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Non-Overhaul Removal and Replacement

Teledyne Continental Motors, Inc.

TM

10-64

IOF-240 Series Engine Maintenance Manual

29 November 2006

4.

Cut, remove, and discard the cable ties from each 25-pin connector.

5.

Remove the safety wire from the 25-pin connector securing screws.

NOTE: The 25 pin connector fasteners are captive in the engine
low voltage harness connector backshell and cannot be removed.

6.

Loosen the two captive fasteners on each connector until fully disengaged from the
SSA.

WARNING

Do not separate the connector from the SSA by pulling on the
harness leads. Pulling on the harness leads can cause
permanent, irreparable damage to the engine low voltage
harness which may result in engine malfunction.

7.

Remove the 25-pin connectors by firmly grasping the edges of the connector
backshell and pull the backshell away from the SSA.

8.

Refer to (Figure 10-54); remove and discard the EMI gaskets and environmental seals
from each connector.

9.

Place protective covers over each of the 25-pin connectors.

10.

Remove two sets of hold down washers, washers, and nuts from SSA signal
conditioner. Remove the SSA signal conditioner from the accessory case.

11.

Temporarily secure the SSA signal conditioner near the lower left engine mount with
a cable tie.

12.

Remove and discard the signal conditioner gasket from the accessory case.

13.

Drain the engine oil from the oil sump (Chapter 9, Engine Oil Servicing).

14.

Follow the “Engine Oil Sump Removal” instructions in Chapter 6 of the TCM
Overhaul Manual (OH-22).

15.

Cut the wire tie temporarily securing the SSA signal conditioner (installed earlier).

16.

Remove the SSA from the engine.

10-11.6. Signal Conditioner Installation

Procedure

1.

Disconnect electrical power to the engine.

2.

Clean the crankcase and accessory case SSA gasket sealing surfaces.

3.

Install the Speed Sensor Assembly along with the Oil Sump according to the “Oil
Sump Installation” instructions in Chapter 11 of the Overhaul Manual (OH-22)

4.

Fill the oil sump to the specified capacity (Chapter 9, “Engine Oil Servicing") and
install the oil gauge rod.

5.

Cut and remove the wire tie temporarily securing the SSA signal conditioner.

6.

Apply Gasket Maker to both sides of the signal conditioner gasket.

7.

Install the signal conditioner with a gasket on the left magneto drive pad.

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Summary of Contents for IOF-240-B

Page 1: ...IOF 240 B Publication M 22 Change 2 2007 TELEDYNE CONTINENTAL MOTORS INCORPORATED DEC 2007 CONTINENTAL AIRCRAFT ENGINE MAINTENANCE MANUAL TECHNICAL PORTIONS OF THIS MANUAL ARE FAA APPROVED ...

Page 2: ...1 9 1 9 1 thru 9 17 0 1 10 0 9 18 thru 9 22 1 2 1 thru 2 21 1 10 1 thru 10 6 1 2 22 2 10 7 thru 10 8 0 2 23 thru 2 26 1 10 9 thru 10 15 1 3 1 thru 3 11 1 10 16 thru 10 43 0 3 12 thru 3 16 0 10 44 thru 10 55 1 3 17 1 10 56 thru 10 57 0 3 18 thru 3 21 0 10 58 thru 10 59 1 3 22 thru 3 23 1 10 60 thru 10 66 0 3 24 thru 3 25 0 10 67 thru 10 69 1 3 26 1 10 70 thru 10 77 0 3 27 thru 3 29 0 10 78 thru 10 ...

Page 3: ...e oil seals Oil seal replacement N A N A M87 15 Alternator Ground Strap Alternator Replacement N A N A M88 9 Lightning Strikes Unscheduled Maintenance Inspections Chapter 7 M88 10 Contaminated Fuels Unscheduled Maintenance Inspections Chapter 7 M89 9 Excessive Crankcase Pressure Unscheduled Maintenance Inspections Chapter 7 M90 13 Exhaust Valve Stem Corrosion Erosion Inspection and Overhaul N A N ...

Page 4: ...hroughout CSB97 10A Piston Pin Plug Wear Service Limits Cylinder Removal and Replacement Chapter 10 CSB98 1B Intake and Exhaust Valve Inspection Service Limits Cylinder Removal and Replacement Chapter 10 SIL98 6B Fuel Injection System Application Guide N A N A N A SIL98 9A Time Between Overhaul Periods Engine Specifications Scheduled Maintenance Overhaul Periods Chapter 2 Chapter 7 SIL99 1 Engine ...

Page 5: ... SIL05 3 Engine Specification Numbers Engine Specification Engine Designation Chapter 2 SIL06 4 FADEC Health Status Annunciator Indications Engine Operating Characteristics N A N A Service Bulletins Released After Publication TCM strives to provide clear concise and accurate information and instructions based on best known engineering data at the time of publication Ongoing process improvements at...

Page 6: ...ntenance Manual 29 November 2006 Mandatory and Critical Service Bulletins Published After this Manual Document Number Title Affected Section s in this Manual Other Service Documents Published After This Manual Document Number Title Affected Section s in this Manual ...

Page 7: ...use is authorized Installation of non TCM parts on a TCM engine constitutes a deviation from TCM type design criteria TCM has not participated in design test or certification of any non TCM parts TCM does not provide product manufacturing specifications to aftermarket parts manufacturers and accepts no liability for the suitability durability longevity or safety of such parts installed on TCM engi...

Page 8: ...epair and Replacement 10 1 Appendix A Glossary A 1 Appendix B Torque Specifications B 1 Appendix C Standard Practices C 1 OVERHAUL MANUAL OH 22 Chapter 1 Introduction 1 1 Chapter 2 Engine Description 2 1 Chapter 3 Special Tools and Supplies 3 1 Chapter 4 Airworthiness Limitations 4 1 Chapter 5 Engine Removal and Installation 5 1 Chapter 6 Engine Disassembly 6 1 Chapter 7 Component Disassembly 7 1 ...

Page 9: ... 1 1 1 1 Scope and Purpose of This Manual 1 2 1 1 1 Advisories 1 3 1 1 2 Using this Manual 1 3 1 1 3 Compliance 1 4 1 1 4 Order of Precedence 1 5 1 2 Publications 1 6 1 2 1 Service Documents 1 6 1 2 2 Related Publications 1 7 1 2 3 Publication Access 1 8 1 2 4 Publication Changes 1 8 1 3 TCM Contact Information 1 9 LIST OF TABLES Table 1 1 Related Publications 1 7 ...

Page 10: ...ons regarding access to TCM publications and a list of other manuals that will enable the mechanic to perform the procedures required to maintain the engine s airworthiness Chapter 2 contains a detailed engine description including engine specifications and operating limits Chapter 3 lists special tool and supply requirements as well as vendor contact information Chapter 4 contains FAA airworthine...

Page 11: ...s for Continued Airworthiness ICAs prepared by TCM and approved by the FAA TCM prepared this manual in a user friendly format suited equally for electronic viewing and print Figures in this manual are for reference only depicting the most prominent configuration in the engine series Consult the parts catalogs for an illustrated parts breakdown of your specific engine and each subsystem Teledyne Co...

Page 12: ... and applies the knowledge training and experience commensurate with the requirements to meet the prerequisite FAA license and certification requirements No other use is authorized WARNING Failure to comply with ICAs may result in injury or subsequent engine failure Pursuant to Federal Aviation Regulation FAR 43 13 each person performing maintenance alteration or preventive maintenance on an engin...

Page 13: ...ne Flight Manual Pilot s Operating Handbook AFM POH while operating the aircraft unless the AFM POH directs otherwise Refer to the AFM POH published by the airframe manufacturer for operating instructions and specifications relative to your aircraft WARNING New or updated Instructions for Continued Airworthiness may be contained in TCM Service Documents Service Documents applicable to the engine o...

Page 14: ...ates to TCM s Instructions for Continued Airworthiness to address a safety issue Category 2 Critical Service Bulletin CSB This category identifies a condition that threatens continued safe operation of an aircraft persons or property on the ground unless some specific action inspection repair replacement etc is taken by the owner or operator Documents in this category are candidates for incorporat...

Page 15: ...urer TCM Publications Installation and Operation Manual OI 22 Yes Yes Yes N A Overhaul Manual OH 22 No Yes Yes N A Parts Catalogues No Yes No N A Detailed Model Specifications No No Yes N A Service Documents No Yes Yes N A Material Handling Specifications MHS No No Yes N A Supplier Bulletins FAA Airworthiness Directives No Yes No N A Accelagold No Reference No Yes Emhart Fastening Teknologies No R...

Page 16: ...t expedient manner WARNING New information may be contained in Teledyne Continental Motors service documents Service documents applicable to engines and accessories within the scope of this manual must be complied with as defined in these documents This manual together with TCM s Installation and Operation Manual OI 22 Service Documents and other related publications noted constitute the Instructi...

Page 17: ...rect information which adversely affects safety 1 3 TCM Contact Information Teledyne Continental Motors is available to answer technical questions and encourages suggestions regarding products parts or service If customers have an inquiry or require technical assistance they should contact their local TCM distributor or TCM field representative To contact TCM refer to the contact information below...

Page 18: ...Introduction Teledyne Continental Motors Inc TM 1 10 IOF 240 Series Engine Maintenance Manual 29 November 2006 This Page Intentionally Left Blank ...

Page 19: ...Drive Train 2 6 2 2 3 Accessory Case 2 8 2 2 4 Cylinders 2 10 2 2 5 Lubrication System 2 12 2 2 6 Ignition System 2 14 2 2 7 Fuel System 2 15 2 2 8 Starter Assembly 2 18 2 2 9 Alternator 2 19 2 2 10 Engine Cooling 2 19 2 2 11 Induction System 2 20 2 3 Engine Specifications and Operating Limits 2 21 2 3 1 Accessory Drive Ratios 2 23 2 3 2 Oil Specifications 2 23 2 3 3 Performance Data 2 24 LIST OF ...

Page 20: ... 2 7 Figure 2 7 Camshaft Gear 2 8 Figure 2 8 Accessory Case 2 9 Figure 2 9 Cylinder Assembly 2 10 Figure 2 10 Lubrication Schematic 2 12 Figure 2 11 Oil Pump 2 13 Figure 2 12 Oil Cooler Adapter 2 14 Figure 2 13 Fuel Injection System 2 15 Figure 2 14 Fuel Pump 2 16 Figure 2 15 Fuel Injector Nozzle 2 17 Figure 2 16 Starting System 2 18 Figure 2 17 Engine Cooling Airflow 2 19 Figure 2 18 Typical Cros...

Page 21: ...rs An engine driven positive displacement vane fuel pump supplies fuel as required to the injectors The fuel pump is directly driven at the same speed as the crankshaft Therefore fuel flow and fuel pressure vary directly with engine speed Fuel exits the pump passes through a 32 micron fuel filter situated between the engine driven fuel pump and the fuel distribution block where it filters particul...

Page 22: ... Cubic Inch Displacement FADEC equipped Fuel Injected B Shipping Designation Figure 2 1 Engine Model Identifier 2 1 2 Cylinder Number Designations Refer to Figure 2 2 The front of the engine is the end closest to the propeller and the rear of the engine is the accessory end Viewed from the rear of the engine the left side cylinders are designated by even numbers 2 4 with Cylinder 2 being closest t...

Page 23: ...hing cylinder base flanges The fuel pump mounting pad is located on the left crankcase half forward of Cylinder 4 Cylinder mounting pads on the left crankcase beyond the corresponding pads on the right crankcase permit each connecting rod to work on a separate crankpin The crankcase interior is vented by a breather assembly comprised of a tube and baffle assembly with a side extension for a hose a...

Page 24: ...ty steel and has three machined main journals which are supported by precision bearing inserts in each of the three bearing saddles machined in the crankcase Four machined rod journals provide attachment of the connecting rod assemblies The crankshaft gear is indexed on the crankshaft by a dowel and secured by machined bolts A neoprene oil seal over the crankshaft flange is seated between the cran...

Page 25: ...ZE BUSHING CONNECTING ROD CONNECTING ROD CAP ROD BOLT SHELL BEARING 2 2 2 3 Camshaft The camshaft forging is machined on three main journals six cam lobes and the gear mount flange at the rear of the camshaft The lobes and journals are ground and hardened The main journals of the camshaft are supported in the crankcase by machined bearing saddles Hydraulic tappets move inward and outward in their ...

Page 26: ... is attached to the rear of the engine crankcase aligned with crankcase dowels the accessory case is secured to the crankcase by crankcase studs and various attaching hardware Accessory mount pads on the rear surface are machined in one plane parallel to the machined parting flange which surrounds the front side of the casting Mounting pads for the magnetos alternator cover starter tachometer driv...

Page 27: ...d end of the oil pump driven gear shaft STARTER MOUNTING PAD MAGNETO MOUNTING PAD COVERED TACH DRIVE MOUNTING PAD ALTERNATOR MOUNTING PAD OIL SCREEN HOUSING MOUNTING PAD OIL PRESSURE RELIEF VALVE HOUSING OIL PUMP SPEED SENSOR PAD INSIDE VIEW OF ACCESSORY CASE STARTER MOUNTING PAD MAGNETO MOUNTING PAD COVERED TACH DRIVE MOUNTING PAD ALTERNATOR MOUNTING PAD OIL SCREEN HOUSING MOUNTING PAD OIL PRESSU...

Page 28: ...xhaust valve and is locked to the stem by tapered semi circular keys which engage grooves around the valve stems An outer retainer holds two concentric springs which surround the intake valve and is locked to the stem by tapered semi circular keys which engage grooves on the stem IOF 240 engines use a cross flow cylinder head design The intake ports are located on top of the cylinder head while th...

Page 29: ...ITE COATED SKIRT 1ST COMPRESSION RING 2ND COMPRESSION RING OIL CONTROL RING OIL SCRAPER RING 2 2 4 2 Hydraulic Valve Tappets The hydraulic lifter performs two functions First it provides an interface between the camshaft lobe and the remaining valve train Hydraulic valve lifters ride on the eccentric cam lobes opening and closing the intake and exhaust valves mechanically via push rod tubes and ro...

Page 30: ...ion Schematic 2 2 5 1 Oil Pump The engine driven gear type oil pump Figure 2 11 is a positive displacement pump that consists of two meshed steel gears that revolve inside the oil pump cavity machined in the accessory case The camshaft drives the oil pump drive gear which drives the oil pump driven gear The oil pump driven gear is supported by a shaft pressed into the accessory case and supported ...

Page 31: ...vice retains the combined dip stick filler cap The dipstick is marked in quarts to the full mark 2 2 5 3 Oil Pressure Relief Valve A machined threaded boss is located on the lower right side of the accessory case for installation of a non adjustable oil pressure relief valve Its passages are connected to the oil pump outlet passage This valve opens when the oil pump pressure exceeds the specified ...

Page 32: ... cylinders ECU 1 fires the top and bottom spark plugs for Cylinders 1 2 ECU 2 fires the top bottom spark plugs for Cylinders 3 4 The ECU control channel emits an ignition pulse through the high voltage harness to fire the top spark plug on the compression stroke and the bottom spark plug on the exhaust stroke for the opposing cylinder The high voltage harness carries high voltage energy from the E...

Page 33: ... FUEL INJECTOR NOZZLE FUEL PRESSURE SENSORS FUEL DISTRIBUTION BLOCK 32 MICRON FILTER 10 MICRON FILTER GROUND FUEL PUMP OUTLET PRESSURE FUEL INLET FROM AIRCRAFT SUPPLY RETURN TO AIRCRAFT SUPPLY LEGEND BY PASS SOLENOID CONTROL PULSE FROM FADEC MPC CONTROLS AMOUNT OF FUEL FUEL PUMP CONTROL SIGNAL FROM BOOST PUMP VARIABLE PULSEWIDTH FUEL INJECTOR NOZZLE FUEL PRESSURE SENSORS FUEL DISTRIBUTION BLOCK 32...

Page 34: ...The fuel pump is directly driven at the same speed as the crankshaft Therefore fuel flow and fuel pressure vary directly with engine speed An adjustable relief valve maintains pump flow and pressure for the lower engine speeds while an adjustable orifice controls fuel pump pressure for the higher engine speeds This combination of mechanical control circuits ensures proper pump pressure and deliver...

Page 35: ...l coil of the fuel injector assembly When the current is ON fuel flows through the injector The ON time for a given injection event is referred to as the injection duration The control channel receives information from the FADEC System sensors and uses this information to determine the appropriate injection duration for the next air intake cycle Each control channel will independently vary cylinde...

Page 36: ...ccessory case at the rear of the engine The lightweight starter employs a clutch assembly which engages the crankshaft to turn the engine TCM offers an optional rear mounted 12 volt starter motor Starter Crankshaft Camshaft Starter Crankshaft Camshaft Figure 2 16 Starting System 2 18 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 37: ...scription of TCM alternators refer to TCM Alternator Service Instructions 2 2 10 Engine Cooling The engine cylinders are cooled by transferring heat from the cylinder barrel and cylinder head cooling fins to the surrounding airflow The airframe engine cowling baffles and baffle seals direct cooling air which is ram air induced by the aircraft s forward speed evenly around the cylinders This airflo...

Page 38: ...PEN THROTTLE position When tripped the TPS signals the ECU that maximum power is required which causes the FADEC System to instantly set the fuel to air ratio for Best Power This feature is necessary on fixed pitch applications as maximum rated engine power is not achievable during take off roll and climb where best power is needed TOP VIEW OF ENGINE THROTTLE VALVE RISER CYL NO 4 RISER CYL NO 2 IN...

Page 39: ... change in throttle inlet air temperature Correction must also be made for the effect of exhaust backpressure and accessory drive losses Contact TCM engineering for correction factors for specific applications Fuel System Specifications Fuel Control System FADEC Electronic Sequential Port Fuel Injection Fuel Minimum Grade 100 or 100LL Russian Commonwealth of Independent States B95 130 People s Rep...

Page 40: ...0 F 116 C Minimum Take off Oil Temperature 75 F 24 C Cruise Flight Operation Oil Temperature 170 220 F 77 104 C Oil Sump Capacity 6 quarts Useable Oil 16 Nose Up 3 0 quarts Useable Oil 10 Nose Down 3 0 quarts Recommended Oil Grade SAE above 40 F 50 or Multi Viscosity Recommended Oil Grade SAE below 40 F 30 or Multi Viscosity Oil Grade TCM Specification MHS 24 CAUTION Oil must be aviation oil confo...

Page 41: ...tion that has been modified for speed torque and moment The drive pad is provided with a cover in the event that its use is not required The drive pad does not incorporate an oil supply only dry vacuum pumps may be used 2 3 2 Oil Specifications WARNING Do not use any engine oil other than those specified The commercially available ashless dispersant aviation oils listed in Recommended Ashless Disp...

Page 42: ...t STANAG as interchangeable with oils qualified under J1899 or J1966 and assigned NATO Codes 0 123 and 0 128 shall be considered qualified under MHS 24 2 3 3 Performance Data Refer to the applicable TCM Detailed Model Specification For complete engine technical specifications installation requirements certification data and engine test stand performance WARNING The performance charts included in t...

Page 43: ...er 20 25 30 35 40 45 50 55 60 65 70 75 80 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 Corrected Brake Horsepower CBHP Fuel Flow lbs hr 45 Power 55 Power 65 Power 75 Power Normal Prop Load Hot Head Prop Load Max Rich IOF 240 Series Engine Maintenance Manual 2 25 31 August 2007 Change 1 ...

Page 44: ... August 2007 Figure 2 20 IOF 240 B Sea Level Performance 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Absolute Dry manifold Pressure ADMP in Hg Corrected Brake Horsepower CBHP 2100 RPM 2800 RPM Speed Lines in 100 RPM Steps Full Rich Fuel Flow ...

Page 45: ... 1 4 Mechanic s Tools 3 24 3 2 Lubricants Sealants and Adhesives 3 25 3 2 2 Oil Change Intervals 3 27 3 2 3 Additives 3 27 LIST OF TABLES Table 3 1 Special Tool List 3 3 Table 3 2 Tool Accessory and Supply Vendors 3 9 Table 3 3 Illustrated Special Tools 3 11 Table 3 4 Mechanic s Tools 3 24 Table 3 5 Qualified Ashless Dispersant Lubricating Oils 3 26 Table 3 6 Break in Oil 3 26 Table 3 7 Preservati...

Page 46: ...nding Tool 3 15 Figure 3 8 Rosan stud Removal Tool 3 15 Figure 3 9 Rosan stud removal tool installed on stud 3 15 Figure 3 10 Alternator Drive Hub Holding Fixture 3 16 Figure 3 11 Alternator Drive Hub Torque Tool 3 16 Figure 3 12 Valve Gauge Line Inspection Fixture 3 17 Figure 3 13 Oil Seal Installation Tool 3 18 Figure 3 14 MT500260 Oil Seal Tool 3 18 Figure 3 15 Staking Tool 3 19 Figure 3 16 Sta...

Page 47: ...it Electrical Harness Troubleshooting TCM 655857 Speed Sensor Assembly Simulator FADEC Fuel Delivery Troubleshooting TCM 655870 FADEC Timing Tool FADEC Sensor Set Troubleshooting TCM 655869 Differential Pressure Tester Cylinder Leak Check Eastern Technology Corporation U S Industrial Tool and Supply Kent Moore Model E2M Model E2A Model TP 104 7251 Master Orifice Tool Cylinder Differential Pressure...

Page 48: ...s McMaster Carr Supply Company Rosan Stud Remover Rosan is a registered trademark of Fairchild Aerospace Fastener Division Removing Rosan Studs McMaster Carr Supply Company 2769A13 Rosan Lock Ring Installer Installing Rosan Studs Kent Moore 8074 Spark Plug Insert Replacer Spark Plug Helicoil Insert Installation Borroughs 4918 Spark Plug Insert Remover Spark Plug Helicoil Insert Removal Borroughs 4...

Page 49: ...case Through Bolt Remover Crankcase Disassembly Borroughs 8114 8 Valve Seat Grinder Set Sioux Brand Machining Intake Or Exhaust Valve Seats Aircraft Tool Supply 1675 Valve Seat Grinder Pilot Machining Intake Or Exhaust Valve Seats Aircraft Tool Supply AEX 375 Intake Valve Seat Grinding Stone Roughening Machining Intake Or Exhaust Valve Seats Aircraft Tool Supply K498 K28 Intake Valve Seat Grinding...

Page 50: ... High Speed Steel Reamer Valve Guide Reaming Kent Moore 2847 1HP 2847 2HP 3606 HP Valve Guide Boss Reamers Valve Guide Reaming Kent Moore 4943 1 HS through 5HS Floating Holder Valve Guide Replacement Borroughs 3170 Plug Gauge Cylinder Intake Valve Guide Inspection Kent Moore 2848 1 Rocker Arm Bushing Remover Installer Rocker Arm Bushing Single Bushing Type Replacement Kent Moore 8118 Rocker Arm Bu...

Page 51: ...ional Inspection with air gage MAHR Federal Staking Tool Throttle Body Assembly Fabricate per specifications in Figure 3 15 through Figure 3 18 Miniature Wedge 45 shear wave TCM 654484 Miniature Wedge 45 shear wave TCM 654578 Miniature Wedge 45 shear wave TCM 654484 Portable Ultrasonic Instrument Crankshaft Ultrasonic Inspection Krautkramer Branson Krautkramer Branson part numbers USK 7D OR7S USL ...

Page 52: ...umber 291 678 000 Transducer 5 0 MHz 0 125 diameter Cylinder Barrel Ultrasonic Inspection Krautkramer Branson Krautkramer Branson part number SMSWS 113 214 585 Cable 6 feet MMD to BNC Cylinder Barrel Ultrasonic Inspection Krautkramer Branson Krautkramer Branson part number C 047 Filter microhenry BNC to BNC Cylinder Barrel Ultrasonic Inspection Krautkramer Branson Krautkramer Branson part number 2...

Page 53: ...nd MI 48686 517 496 6000 or for distributor 800 248 2481 dowcorning com Eastern Electronics See Eastern Technology Corporation Eastern Technology Corporation 180 Roberts St East Hartford CT 06108 1 860 528 9821 easterntech com Electro systems See Kelly Aerospace Emhart Fastening Teknologies Industrial Division 50 Shelton Technology Ctr P O Box 859 Shelton CT 06484 USA 203 924 9341 203 925 3109 emh...

Page 54: ...41 parkreascorp com Shell Oil Company P O Box 4320 Houston TX 77210 713 241 4819 713 241 6511 shell lubricants com Snap On Tools 877 740 1900 877 740 1880 snapon com L S Starrett Company 800 541 8887 978 249 3551 978 249 8495 starrett com Tanair Tanis Aircraft Services P O Box 117 Glenwood MN 56334 800 443 2136 800 862 2443 800 443 2136 tanair com Turco Henkel Aerospace Aerospace Structural Adhesi...

Page 55: ... Expanding Tool Figure 3 7 Rosan stud Removal Tool Figure 3 8 Alternator Drive Hub Holding Fixture Figure 3 10 Alternator Drive Hub Torque Tool Figure 3 11 Valve Gauge Line Inspection Fixture Figure 3 12 Oil Seal Installation Tool Figure 3 13 MT500260 Oil Seal Tool Figure 3 14 Staking Tool Figure 3 15 Valve Guide Seal Installation Tool Figure 3 19 O Ring Installation Tool Figure 3 20 FADEC Timing ...

Page 56: ...aster Orifice Tool FACTORY CALIBRATED ORIFICE SPARK PLUG THREADS 18mm DUST CAP DUST CAP Figure 3 3 Master Orifice Tool used with pressure tester E2A The Master Orifice Tool restrictor orifice dimensions for these engines must be 0 040 inch orifice diameter 0 250 inch long with 60 approach angle The airflow rate should be 120 5 cubic feet per hour at 30 psi differential pressure ...

Page 57: ...Teledyne Continental Motors Inc TM Special Tools and Supplies IOF 240 Series Engine Maintenance Manual 3 13 29 November 2006 Figure 3 4 Borescope Autoscope Figure 3 5 Helical Coil Extraction Tool ...

Page 58: ...Special Tools and Supplies Teledyne Continental Motors Inc TM 3 14 IOF 240 Series Engine Maintenance Manual 29 November 2006 Figure 3 6 Helical Coil Insertion Tool Figure 3 7 Helical Coil Expanding Tool ...

Page 59: ...yne Continental Motors Inc TM Special Tools and Supplies IOF 240 Series Engine Maintenance Manual 3 15 29 November 2006 Figure 3 8 Rosan stud Removal Tool Figure 3 9 Rosan stud removal tool installed on stud ...

Page 60: ...Tools and Supplies Teledyne Continental Motors Inc TM 3 16 IOF 240 Series Engine Maintenance Manual 29 November 2006 Figure 3 10 Alternator Drive Hub Holding Fixture Figure 3 11 Alternator Drive Hub Torque Tool ...

Page 61: ...Teledyne Continental Motors Inc TM Special Tools and Supplies Ø 2 50 Ø 2 50 Figure 3 12 Valve Gauge Line Inspection Fixture IOF 240 Series Engine Maintenance Manual 3 17 31 August 2007 Change 1 ...

Page 62: ...ies Engine Maintenance Manual 29 November 2006 Figure 3 13 Oil Seal Installation Tool Medium Knurl Mill Flat Stamp P N On Flat 1 16 Radius 0 783 Dia 1 200 Dia 1 00 0 68 5 16 1 1 4 Dia Before Knurl 1 8x45 1 00 2 00 3 00 Material 1020 Case Harden Figure 3 14 MT500260 Oil Seal Tool ...

Page 63: ...Teledyne Continental Motors Inc TM Special Tools and Supplies IOF 240 Series Engine Maintenance Manual 3 19 29 November 2006 Figure 3 15 Staking Tool Figure 3 16 Staking Tool Bill of Materials ...

Page 64: ...Special Tools and Supplies Teledyne Continental Motors Inc TM 3 20 IOF 240 Series Engine Maintenance Manual 29 November 2006 Figure 3 17 Staking Tool Dimensions A ...

Page 65: ...Teledyne Continental Motors Inc TM Special Tools and Supplies IOF 240 Series Engine Maintenance Manual 3 21 29 November 2006 Figure 3 18 Staking Tool Dimensions B ...

Page 66: ... Tools and Supplies Teledyne Continental Motors Inc TM Figure 3 19 Valve Guide Seal Installation Tool Figure 3 20 O Ring Installation Tool 3 22 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 67: ...l Figure 3 22 SSA Simulator USB to Serial Adapter EDI Serial Data Cable EDI Serial Data Cable EDI Data Interface USB to Serial Adapter EDI Serial Data Cable EDI Serial Data Cable EDI Data Interface Figure 3 23 PowerLink FADEC Serial Data Cable IOF 240 Series Engine Maintenance Manual 3 23 31 August 2007 Change 1 ...

Page 68: ... Micrometers Ballpeen hammer Allen wrenches assortment Pullers Slotted screwdrivers assortment Blind Bearing Remover Phillips screwdrivers Nos 1 and 2 Vernier calipers Safety wire pliers Leather or soft plastic mallet Common pliers Small hole gauges thickness gauges Diagonal cutter pliers Feeler gauges leaf type Needle nose pliers C clamps Duck bill pliers Brass wire brush Snap ring pliers with 90...

Page 69: ...Continental Motors listing of accepted SAE J 1899 oils by manufacturer and brand name is for the convenience of our customers Always refer to the label on the oil to ensure that the oil meets the appropriate SAE specification QPL J 1899 Qualified Products List is available from SAE Headquarters 400 Commonwealth Drive Warrendale PA 15096 001 The Naval Air Systems Command maintains QPL J 1899 and QP...

Page 70: ...i wear Formulation Shell USA Aeroshell Oil W100 Plus W80 Plus Sinclair Oil Company Sinclair Avoil Texaco Inc Texaco Aircraft Engine Oil Premium AD Total France Total Aero DM 15W 50 Union Oil Company of California Union Aircraft Engine Oil HD Table 3 6 Break in Oil TYPE EQUIVALENT APPLICATION SAE J 1966 Aviation replaces MIL L 6082 non dispersant mineral lubricating oil for piston aircraft engines ...

Page 71: ...re formulated primarily for automotive and industrial engine applications From time to time we receive inquiries regarding use of these products in our aircraft engines Most of these additives and concentrates while they may be highly beneficial to automotive and industrial operation are not compatible with air cooled light aircraft engines in their operating environments With the exception of the...

Page 72: ...Piston Pins Piston Rings Thrust Washers Oil Filter adapter seals Grade 50 Break in Non compounded Aviation Oil SAE J 1966 O Rings All models Dow Corning G N Paste Camshaft lobes and tappet faces At engine assembly Shell Alvania 2 P N 654561 Apply a light coat to ignition lead point of contact between nut seat and ferrule All models Shell 5 MIL G 3545 C Grease P N 654468 1 1 Gallon Can Fuel injecti...

Page 73: ...ankcase and sump gasket oil pump covers All models Between oil sump and sump gasket All models with non beaded gaskets P N 646942 Gasket Maker or Loctite 515 Gasket Eliminator 642910 OIL SEAL O D of all uncoated oil seals except fuel pump adapter seal Applicable models Cam bore cover gasket except beaded gaskets 240 470 520 550 GTSIO 520 Intake manifold gaskets All press type plugs Hubbard etc All...

Page 74: ...e screws All Models Starter clutch assembly bearing O D Loctite 609 Adhesive Sealant P N 654562 1 50 ml P N 654562 2 250ml Fuel pump adapter seal Fuel pump shaft seal All Models P N 654470 1 3M Brand EC 1252 White Spot Seal Putty Air throttle fuel metering assembly Magneto flanges Cylinder deck stud nuts through bolts Fuel pump manifold valve throttle and control fittings All Models P N 655114 1 A...

Page 75: ...tenance Manual 4 1 29 November 2006 Chapter 4 AIRWORTHINESS LIMITATIONS CONTENTS Chapter 4 Airworthiness Limitations 4 1 4 1 Mandatory Replacement Times 4 2 4 2 Mandatory Inspection Intervals 4 2 4 3 Other Related Procedures 4 2 4 4 Distribution of Changes to Airworthiness Limitations 4 2 ...

Page 76: ...e engines covered in this manual do not require specific intervals of inspection pursuant to type certification 4 3 Other Related Procedures Subject to additional information contained in Airworthiness Directives issued after the date of certification there are no other related procedures required pursuant to the type certification for the engines covered in this manual 4 4 Distribution of Changes...

Page 77: ... November 2006 Chapter 5 ENGINE REMOVAL AND INSTALLATION Refer to abbreviated engine removal and installation procedures in Chapter 5 of the TCM Overhaul Manual OH 22 to remove and install the same engine for maintenance Detailed engine installation procedures are in the TCM Installation and Operation Manual OI 22 ...

Page 78: ...Engine Removal and Installation Teledyne Continental Motors Inc TM 5 2 IOF 240 Series Engine Maintenance Manual 29 November 2006 This Page Intentionally Left Blank ...

Page 79: ...ONAL PERFORMANCE CHECKS CONTENTS Chapter 6 Operational Performance Checks 6 1 6 1 Engine Operational Check 6 2 6 1 1 Maintenance Preflight Inspection 6 3 6 1 2 Test Equipment Setup 6 4 6 1 3 FADEC Engine Operational Check 6 7 6 2 Operational Checklist 6 12 LIST OF TABLES Table 6 1 Engine Operation Prerequisites 6 2 Table 6 2 Operational Checklist 6 13 ...

Page 80: ...A with battery condition monitor WARNING Complete Table 6 1 tasks on a newly installed routinely inspected repaired or overhauled engine before releasing the aircraft for service DO NOT FLY THE AIRCRAFT UNTIL FLIGHT PREREQUISITES HAVE BEEN MET Table 6 1 Engine Operation Prerequisites Sequence Requirement Section References 1 Prepare the Engine for Operation Maintenance Preflight Inspection 2 Check...

Page 81: ...ified for operation with 100 LL Blue or 100 Green aviation fuel If the minimum grade required is not available use the next higher grade Never use a lower grade fuel Using lower octane rated fuel or jet fuel will result in damage to or destruction of an engine the first time high power is applied This would most likely occur on take off If the aircraft is inadvertently serviced with the wrong fuel...

Page 82: ... has been exposed to ambient temperatures between 20 to 40ºF 7 to 4 C refer to instructions in Cold Weather Starting without Preheating in Chapter 7 Engine Operation of the TCM Installation and Operation Manual OI 22 6 1 2 Test Equipment Setup The Operational Check requires either a FADEC diagnostics computer or calibrated gauges Calibrated Gauges may be used to verify fuel system setup only To ve...

Page 83: ...wivel tee and torque 6 Connect the 0 100 psi gauge to the swivel tee using a hose long enough to provide proper clearance from the engine cowling and propeller arc Torque all connections Refer to Figure 6 3 7 Operate the aircraft boost pump in accordance with the Aircraft POH procedures 8 Loosen the test hose connection to the 0 100 psi gauge to bleed the lines of air 9 Position and maintain the g...

Page 84: ...Operational Performance Checks Teledyne Continental Motors Inc TM Figure 6 3 0 100 psi Gauge Installed to Check Fuel Pressure 6 6 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 85: ...The FADEC CAUTION and FADEC WARN lamps are OFF WARNING Flight is prohibited if all of the steps in this operational test are not completed If during an operational test or engine warm up any operational abnormalities or leaks occur do not take off Determine the cause of the problem or leak and take corrective action necessary to maintain engine airworthiness WARNING Ensure the propeller arc is cle...

Page 86: ...ng according to instructions in the TCM Overhaul Manual OH 22 Reface the pressure relief valve seat or replace the plunger and seat as required 14 Oil pressure Check RESULT Oil pressure indicates 30 60 psi If no oil pressure is noted shut down the engine and investigate the cause 15 Throttle 850 RPM idle speed RESULT Maintain idle speed for 1 minute 16 Fuel Selector ON Fullest tank or BOTH WARNING...

Page 87: ...Switch Toggle OFF ON RESULT No RPM drop Verify both the FADEC CAUTION and FADEC WARN lamps are OFF If a dedicated backup battery is used as a Secondary Power Source the PPWR FAIL lamps will come ON then OFF The EBAT FAIL lamp may come ON 23 FADEC Secondary Power Switch Toggle OFF ON RESULT No RPM drop Verify the FADEC CAUTION and WARN lamps are OFF If a dedicated backup battery is used as a Second...

Page 88: ...ne according to the AFM POH 29 Remove test equipment a FADEC Diagnostics Computer 1 Close the Level I Diagnostic application on the PC 2 Disconnect and remove the FADEC serial data interface cable from the aircraft b Calibrated Gauges 1 Remove all test gauges fittings and hoses that were installed for fuel system setup 2 Reconnect support and torque all fuel hoses to their original locations 30 Pe...

Page 89: ...00 32 25 32 50 32 75 33 00 33 25 33 50 33 75 34 00 34 25 34 50 34 75 35 00 35 25 35 50 35 75 36 00 1975 2000 2025 2050 2075 2100 2125 2150 2175 2200 2225 2250 2275 2300 2325 2350 2375 2400 2425 2450 2475 2500 2525 Engine Speed RPM Fuel Pressure PSIG Figure 6 4 Fuel Pressure vs Engine Speed Chart IOF 240 Series Engine Maintenance Manual 6 11 31 August 2007 Change 1 ...

Page 90: ... 240 Series Engine Maintenance Manual Change 1 31 August 2007 6 2 Operational Checklist Make a copy of the Operational Checklist to record operational test results NOTE Operating limits and engine model specifications are located in Chapter 2 Engine Description of this manual ...

Page 91: ...ime New Overhaul Date Location Elevation Outside Air Temp Pressure Alt Fuel System Adjustment RPM MAP EGT Cylinder Head Temp F Oil Static WOT Spec Actual F 1 2 3 4 PSI F Fuel Pressure Unmetered Adjustments Metered Adjustments Target Actual CW CCW Target Actual CW CCW Flight Check Data Pressure Altitude EGT F CHT F RPM WOT Set altimeter to 29 92 Spec Actual Spec Actual Fuel Pressure Oil PSI Oil Tem...

Page 92: ...Operational Performance Checks Teledyne Continental Motors Inc TM 6 14 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 This Page Intentionally Left Blank ...

Page 93: ...7 45 7 3 16 Throttle Position Switch Inspection 7 45 7 3 17 Alternator Inspection 7 46 7 3 18 Ground Strap Continuity Test 7 47 7 4 Unscheduled Maintenance 7 48 7 4 1 Propeller Strike 7 48 7 4 2 Propeller Strike Inspection 7 48 7 4 3 Hydraulic Lock 7 49 7 4 4 Engine Overspeed 7 50 7 4 5 Lightning Strike 7 51 7 4 6 Contaminated Fuel System 7 52 7 4 7 Abnormal Ferrous Material in Oil Analysis 7 52 7...

Page 94: ...Phosphated Cylinder Bore 7 28 Figure 7 12 Cylinder Barrel Scoring and Piston Rub 7 29 Figure 7 13 Typical Wear in Upper Ring Travel Area 7 29 Figure 7 14 Typical Cylinder Wear 7 29 Figure 7 15 Baffle Seals 7 31 Figure 7 16 Improperly Positioned Baffle Seals 7 32 Figure 7 17 Improperly Positioned Aft and Side Peripheral Baffle Seals 7 32 Figure 7 18 Improperly Positioned Aft and Side Peripheral Baf...

Page 95: ...other FAA approved Inspection Program is established the Engine Inspection and Maintenance Schedule Table 7 1 shows the inspections for engines covered in this manual The inspections described in this chapter apply to the engine and not to the aircraft Refer to the Aircraft Maintenance Manual for airframe inspection requirements The inspections are progressive commencing from the date the engine i...

Page 96: ...ng individual cylinder replacement Repeat this inspection after each 25 hours of operation until oil consumption stabilizes Section 7 3 2 25 Hour Initial Operation Inspection 50 4 months 50 hour engine inspection Section 7 3 3 50 Hour Engine Inspection 50 4 months Oil and filter change Engine Oil Servicing in Chapter 9 Maintenance and Adjustments 100 Annually 100 hour engine inspection Section 7 3...

Page 97: ...ine Maintenance Manual 7 5 31 August 2007 Change 1 2a If consumption is acceptable proceed to step 3 a If oil consumption is excessive troubleshoot according to the instructions in Chapter 8 Troubleshooting b Perform a Cylinder Borescope Inspection according to Section 7 3 7 3 c Service the engine with mineral oil conforming to SAEJ1966 rather than ashless dispersant oil in step 4 Repeat this insp...

Page 98: ... 2 Submit an oil sample for analysis according to the instructions in Oil Sample Collection and Spectrographic Oil Analysis in Chapter 9 Maintenance and Adjustments 3 Change the oil and filter according to the Oil Change Procedure in Engine Oil Servicing Fill the oil sump to the proper capacity with approved fresh ashless dispersant oil 4 Perform an Induction System Inspection according to Section...

Page 99: ...ange 1 4 Perform the Cylinder Inspections according to the instructions in section 7 3 7 The cylinder inspections consist of multiple inspections and checks including Cylinder Power Stroke Area Differential Pressure Borescope Baffle and Cylinder Mounting Deck Inspections 5 Perform a Crankcase Inspection according to the instructions in Section 7 3 8 6 Perform an Induction System Inspection accordi...

Page 100: ...ies linder Inspections according to the instructions in Section 7 3 7 5 lug leads Inspect 6 Replace any stressed or broken wire ties 3 Perform an Alternator Inspection according Section 7 3 17 4 For any other optional engine accessories refer to the accessory manufacturer s maintenance manual for inspection criteria 7 3 6 Visual Inspection Procedure 1 Check that the nacelle is clean and free of fu...

Page 101: ...ess 10 Verify the security of the Electronic Control Units ECUs and engine ground straps 11 Verify the security of the Throttle Position Switch TPS and related hardware 12 Verify securing straps and safety wire at the 25 pin speed sensor connectors and 50 pin ECU connectors are present and fastened properly 13 Replace any stressed or broken wire ties 14 Check electrical connectors for signs of cor...

Page 102: ...e must be performed for a complete cylinder inspection 7 3 7 1 Cylinder Visual Inspection Procedure 1 Remove the engine compartment cowling and perform steps 2 and 3 without cleaning the engine 2 Use an inspection light and mirror inspect the cylinder barrel and fins power stroke areas for cracks sharp indentations chafing damage and pitting Figure 7 1 Repair discrepancies according to Chapter 9 O...

Page 103: ...Teledyne Continental Motors Inc TM Maintenance Inspections Figure 7 1 Cylinder Barrel Power Stroke Inspection Areas IOF 240 Series Engine Maintenance Manual 7 11 31 August 2007 Change 1 ...

Page 104: ... of the Cylinder Differential Pressure Test is to identify leaks and the source of leaks with the engine under static conditions not running using a regulated pressure source When performing a Cylinder Differential Pressure Test a regulated test pressure of eighty pounds per square inch 80 PSI is directed into the cylinder with the piston at top dead center at the end of the compression stroke and...

Page 105: ...ability of 15 Cubic Feet per Minute Cylinder Differential Pressure Tester Select one of the following units listed below or equivalent Eastern Technology Corporation Model E2M Figure 7 2 Recommended by TCM This Differential Pressure Tester incorporates the Master Orifice Tool Figure 7 4 Eastern Technology Corporation Model E2A Figure 7 3 This Differential Pressure Tester requires a separate Master...

Page 106: ...engine logbook and the inspection work order Frequency Prior to performing the Cylinder Differential Pressure Check Prior to conducting a Cylinder Differential Pressure Test use the Master Orifice Tool to normalize Differential Pressure Test readings and calibrate the Differential Pressure Tester Refer to Section 7 3 7 2 1 to calibrate the Model E2M Tester or Section 7 3 7 2 2 to calibrate the Mod...

Page 107: ...t 9 Close the Slow Fill Valve completely The handle is vertical and pointing down 10 Set the Master Orifice Valve to the OFF position The handle is horizontal and directly over the OFF label IOF 240 Series Engine Maintenance Manual 7 15 31 August 2007 Change 1 11 The Differential Pressure Tester is ready to be used for the Cylinder Differential Pressure Test in Section 7 3 7 2 4 Figure 7 2 Model E...

Page 108: ... Connect the air source to the tester at the male quick connection fitting 6 Adjust the pressure regulator to 80 psi on the regulator pressure gauge 7 Turn the cylinder pressure valve to the ON or OPEN position 8 If necessary adjust the pressure regulator to maintain a reading of 80 psi on the regulator pressure gauge 9 Record the pressure reading on the cylinder pressure gauge on the Cylinder Ins...

Page 109: ...3 7 2 3 Differential Pressure Tester Reliability Check Keep the Differential Pressure Tester clean and check it periodically for accuracy as follows Procedure 1 Apply a line pressure of 100 to 120 psi close the cylinder pressure valve 2 Adjust the regulator pressure valve to 80 psi The pressure in both gauges should stabilize with no leakage IOF 240 Series Engine Maintenance Manual 7 17 31 August ...

Page 110: ... PRESSURE GAUGE RESTRICTOR ORIFICE REGULATOR PRESSURE VALVE COMPRESSED AIR SOURCE CYLINDER PRESSURE VALVE CYLINDER ADAPTER CYLINDER REGULATOR PRESSURE GAUGE CYLINDER PRESSURE GAUGE RESTRICTOR ORIFICE REGULATOR PRESSURE VALVE COMPRESSED AIR SOURCE CYLINDER PRESSURE VALVE REGULATOR PRESSURE GAUGE CYLINDER ADAPTER MASTER ORIFICE HAND TIGHT Establishing Minimum Acceptable Cylinder Pressure Leakage Lim...

Page 111: ... the piston rings are seated and the piston is square in the cylinder bore move the propeller slightly back and forth with a rocking motion while applying the regulated pressure of 80 psi to obtain the highest indication Adjust the regulator as necessary to maintain a pressure gauge reading of 80 psi 9 Record the pressure indication on the cylinder pressure gauge The difference between this pressu...

Page 112: ...ngine breather Fly aircraft at Cruise Power setting and repeat Cylinder Differential Pressure Test Cylinder Differential Pressure Test reading below leakage limit after re check Not applicable Remove cylinder for repair Air discharge at oil filler crankcase breather Cylinder Differential Pressure Test reading above or below leakage limit Oil consumption abnormal with oil discharge out engine breat...

Page 113: ...er Differential Pressure Test Air discharge into exhaust system Cylinder Differential Pressure Test reading below leakage limit after re check Not applicable Remove cylinder for repair Air escaping at spark plug spot face Cylinder Differential Pressure Test readings not applicable Dye check of area reveals cracks Remove cylinder for replacement Air discharge at cylinder head to barrel juncture or ...

Page 114: ...or Induction System port If air flow is audible the static seal is leaking b If leakage is present around the intake or exhaust valve stake the valves 1 Remove the rocker covers from the applicable cylinder s 2 Inspect the valve springs valve retainers valve stem for wear WARNING Do not stand or place equipment within the arc of the propeller 3 Rotate the propeller so the piston will not be at top...

Page 115: ...r several times to cause the piston rings to reseat to the piston land and possibly re sealing c Re pressurize the cylinder to 80 psi d Check the cylinder pressure gauge reading e Refer to Figure 7 7 Rotate the propeller backward to move the piston over the ring gap when checking the compression if the gap happens to be right at the top or bottom of the cylinder barrel 1 If the cylinder pressure g...

Page 116: ...inder head to barrel seal 2 Spark plug port seal 3 Intake and exhaust ports c Reduce pressure to 0 psi Repeat steps a and b for each cylinder Record the results on Table 7 10 the Cylinder Inspection Checklist d No leakage is allowed in the static seals If leakage is noted between the cylinder head and barrel replace the cylinder according to instructions in Chapter 10 e Refer to the Summary of Sea...

Page 117: ...g Corrective Action Piston cracked or out of limits Replace piston Worn rings Replace rings Test gauge below tolerance Cylinder wall dimensions out of limits Replace cylinder Dynamic Seal Check Piston ring Test gauge above tolerance None None Loose helical coil Replace helical coil Spark Plug to Port Seal Apply soapy solution around spark plug Cracked cylinder Replace cylinder Cylinder Head to Bar...

Page 118: ...wear patterns which can contribute to low differential pressure readings or increased oil consumption The cylinder wall hone pattern consists of engineered surface scratches which aid in ring seating by allowing the ring and wall surface to wear uniformly and provides a reservoir of oil for lubrication during ring travel The cylinder walls and rings are designed to wear over the life of the engine...

Page 119: ... for erosion burning Remove cylinder for repair Sparkplug heli coils for protrusion into combustion chamber Heavy carbon deposits presence of excessive oil Exhaust Valve Face Inspect for signs of leakage or damage indicated by Localized discoloration on the valve face circumference Repair or replace cylinder Figure 7 9 Minute cracks Erosion missing material Intake Valve Face Inspect for signs of l...

Page 120: ...ons moving toward center of valve Combustion chamber has light brown deposits Figure 7 10 Phosphate Coated Cylinder w Revised Cylinder Bore Hone Pattern Figure 7 11 Phosphated Cylinder Bore Phosphate coating in valleys of the cylinder bore hone pattern Light corrosion at top of cylinder bore above piston ring travel limit in this area is normal Phosphate coating provides increased corrosion protec...

Page 121: ... TM Maintenance Inspections Figure 7 12 Cylinder Barrel Scoring and Piston Rub Figure 7 13 Typical Wear in Upper Ring Travel Area Figure 7 14 Typical Cylinder Wear IOF 240 Series Engine Maintenance Manual 7 29 31 August 2007 Change 1 ...

Page 122: ...der according to Cylinder Removal instructions in Chapter 10 Non Overhaul Repair and Replacement 2 Check the cylinder for serviceability 3 Thoroughly clean the cylinder base flange and crankcase mounting deck 4 Replace the cylinder base packing 5 Reinstall the cylinder according to instructions in Chapter 10 Non Overhaul Repair and Replacement 7 30 IOF 240 Series Engine Maintenance Manual Change 1...

Page 123: ...worn or distorted baffles in accordance with the manufacturer or Supplemental Type Certificate STC holder 3 Check and adjust inter cylinder baffles to ensure a tight fit Inspect for holes and cracks that would allow cooling airflow to be wasted Seal any cracks or holes by applying a non corrosive silicone adhesive sealant Consult the aircraft manufacturer for application instructions Baffle condit...

Page 124: ...s Teledyne Continental Motors Inc TM Figure 7 16 Improperly Positioned Baffle Seals Figure 7 17 Improperly Positioned Aft and Side Peripheral Baffle Seals 7 32 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 125: ...otors Inc TM Maintenance Inspections Figure 7 18 Improperly Positioned Aft and Side Peripheral Baffle Seals Figure 7 19 Aft and Side Baffles with Air Gaps IOF 240 Series Engine Maintenance Manual 7 33 31 August 2007 Change 1 ...

Page 126: ...ions Teledyne Continental Motors Inc TM Figure 7 20 Cooling Air Loss Due to Gaps in Baffle Seal Figure 7 21 Cooling Air Loss Due to Gaps in Baffle Seal 7 34 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 127: ...cowl flap Cowl flap operation is an integral part of engine cooling control Frequency During 100 hour or annual inspection Procedure 1 Verify add on accessories and their associated hardware do not restrict cowl inlet cowl outlet and air flow through the cooling fins 2 Verify the cowl flap rigging and operation meet the appropriate aircraft maintenance manual specifications 3 Check for cracks and ...

Page 128: ...s for cracks Carefully inspect the entire external surface of the crankcase using an inspection light and mirror a Cylinder deck white non shaded critical areas cracks regardless of size require immediate crankcase replacement Refer to the affected white areas in Figure 7 22 Figure 7 22 Crankcase Critical White and Non Critical Shaded Areas b Repair cracks one inch 2 54 cm or longer in the shaded ...

Page 129: ...and the oil sump for cracks and dents Replace the oil breather on the crankcase according to instructions in Section 10 8 Replace the oil sump See Section 10 5 if the sump connection is cracked Inspect tube ends for scoring and eccentricity that may cause a bad seal and oil leakage Discard and replace defective components Refer to the aircraft maintenance manual for Air Oil Separator and tubing re...

Page 130: ...filtering element should be repaired as required in accordance with the airframe manufacturer STC holder s information 3 Verify the operation of the alternate air door and the integrity of the seal in the closed position Verify the door operating mechanism closes securely Replace or repair as necessary in accordance with the airframe manufacturer STC holder s information 4 If oil analyses are done...

Page 131: ... in the log book for the backup battery installation date If the elapsed time is greater than 12 months replace the battery according to airframe manufacturer s instructions 2 Disconnect the positive and negative battery terminals on the backup battery 3 Measure the battery voltage If the voltage is less than 10 volts replace the battery according to airframe manufacturer s instructions 7 3 12 Fue...

Page 132: ...ring 100 3 Clean the fuel distribution block parts and filter according to Cleaning instructions in Chapter 9 CAUTION The filter is sensitive to debris and contamination Use only fresh solvent to clean the filter 4 Inspect the cleaned filter verify the filter is clean and free of dents or damage If the filter is damaged replace it with a new filter 5 Install the filter 101 in the fuel distribution...

Page 133: ...distribution block The IOF 240 B1 and B2 specifications feature a 20 micron one piece fuel filter Figure 7 24 installed inline between the fuel pump and the fuel distribution block IOF 240 B4 and B5 specifications use a filter assembly with a removable 32 micron screen Figure 7 26 and a bypass valve Only one of the two filters will be installed on the engine IOF 240 Series Engine Maintenance Manua...

Page 134: ...flushing until no debris is present on the clean white paper filter 5 If the fuel filter housing assembly cannot be thoroughly cleaned replace the entire filter assembly 6 Visually inspect hardware threads and sealing surfaces for wear or rough surfaces Replace worn or rough hardware 7 Install a new O ring and the straight fitting into the filter Torque the fitting per Appendix B 8 Connect the fue...

Page 135: ...n filtered solvent to clean the fuel filter 5 If the fuel filter screen cannot be thoroughly cleaned replace the contaminated component 6 Visually inspect hardware threads and sealing surfaces for wear or rough surfaces Replace worn or rough hardware 7 Insert the filter screen and spring in order into the filter housing 8 Install a new O ring and install the cover with four screws and washers Torq...

Page 136: ... gauge Exhaust gas temperature gauge 7 44 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 NOTE Verify EGT system accuracy The aircraft manufacturer may require EGT reporting be operational for all categories of flight Consult the Aircraft Maintenance Manual for interval and operational requirements In many cases EGT calibration is a100 hour inspection requirement 7 3 14 Engine Con...

Page 137: ...rocedure Perform a cylinder drain inspection to ensure the drain s function properly by performing the following procedure WARNING Do not turn the propeller or allow personnel to stand in the arc of the propeller while performing the following inspection 1 Apply a light vacuum source to the airframe fuel drain outlet 2 Monitor the fuel drain to ensure the drain flows freely 3 Apply a slight positi...

Page 138: ...or Drive Hub Inspection in Section 7 3 17 1 For Belt Driven Alternators proceed to step 3 3 Inspect the alternator according to the manufacturer s instructions 4 Install the alternator according to Alternator Installation instructions in Chapter 10 5 Install airframe components and cowling in accordance with the airframe manufacturer s instructions 7 3 17 1 Alternator Drive Hub Inspection Procedur...

Page 139: ...aircraft ground and each ECUs is connected to the airframe with two ground wires Frequency During 100 hour or annual inspection Procedure 1 Inspect the lead wire for fraying nicks cuts or damage NOTE If the ground strap is dirty or corroded refer to Cleaning a Ground Strap Connection Point in Chapter 9 Maintenance and Adjustments 2 Disconnect one end of a ground strap from the engine or ECU Measur...

Page 140: ...ler are more concentrated in areas that are nicked and cut that then act as stress risers Stress risers can weaken the blade and may eventually cause the blade to fail If a propeller blade is lost the resulting imbalance can cause separation of the entire engine from the airframe causing the center of gravity to extend beyond specified limits rendering the aircraft uncontrollable 7 4 2 Propeller S...

Page 141: ...roper maintenance of the cylinder fuel drain lines Improper starting procedures Failure to properly remove preservative oil from an engine that had been in storage WARNING Do not operate the engine if hydraulic lock is suspected Inspect the engine for hydraulic lock as directed below Procedure 1 Remove all cylinders and connecting rods in accordance with instructions in the Overhaul Repair and Rep...

Page 142: ...ues uncorrected for less than ten seconds no action is required For more than 10 seconds land the plane and proceed as follows Procedure 1 Drain oil and inspect for debris Remove the oil filter and inspect the filter element for debris 2 Remove the rocker covers and inspect the following for damage or debris a Valves b Springs c Rocker arms d Tappets e Spring retainers f Pushrods 3 Inspect compone...

Page 143: ...and bolts Inspect remaining components using service limit tolerances in Chapter 10 Non Overhaul Repair and Replacement and assemble according to instructions in this manual 7 4 4 3 Category III Overspeed conditions in this category are considered excessive Each overspeed case must be evaluated based on factors at the time of the incident Refer to Chapter 1 of this manual for TCM Contact Informati...

Page 144: ...t overhaul Testing chapters in the Overhaul Manual OH 22 7 4 7 Abnormal Ferrous Material in Oil Analysis See Excessive or Abnormal Engine Noise 7 4 8 Excessive or Abnormal Engine Noise If abnormal noise is coming from the engine valve gear or if abnormal amounts of iron and or steel are detected by oil analysis oil filter element or screen examination oil suction screen examination or magnetic dra...

Page 145: ...according to the instructions in the Maintenance Manual heeding all warnings cautions and notes Initial the block beside the procedure upon completion Note discrepancies in the Inspector Comments column Inspection Item Initials Inspector Comments IOF 240 Series Engine Maintenance Manual 7 53 31 August 2007 Change 1 Visual Inspection Section 7 3 6 Determine oil consumption Section 7 3 2 Collect an ...

Page 146: ...Maintenance Inspections Teledyne Continental Motors Inc TM 7 54 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 This Page Intentionally Left Blank ...

Page 147: ...e procedure upon completion Note discrepancies in the Inspector Comments column Inspection Item Initials Inspector Comments Oil Consumption and Trend Monitoring Oil Analysis Profile Established Section 9 1 4 Oil Analysis Laboratory used Date of last oil sample analysis Silicone content of last sample Oil consumption quantity noted during oil change Is oil consumption excessive T Yes T No IOF 240 S...

Page 148: ...Maintenance Inspections Teledyne Continental Motors Inc TM 7 56 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 This Page Intentionally Left Blank ...

Page 149: ... Section 6 1 Oil Consumption and Trend Monitoring Oil Analysis Profile Established Section 9 1 4 Oil Analysis Laboratory used Date of last oil sample analysis Silicone content of last sample Oil consumption quantity noted during oil change Is oil consumption excessive T Yes T No Visual Inspection Section 7 3 6 Accessory Mounting and Security Inspection Section 7 3 5 Cylinder Inspections use Cylind...

Page 150: ...spection Performed by _____________________ Complete the 100 hour inspection according to the instructions in the Maintenance Manual heeding all warnings cautions and notes Initial the block beside the procedure upon completion Note discrepancies in the Inspector Comments column Inspection Item Initials Inspector Comments 7 58 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 Ground...

Page 151: ...d Trend Monitoring Oil Analysis Profile Established Section 9 1 4 Oil Analysis Laboratory used Date of last oil sample analysis Silicone content of last sample Oil consumption quantity noted during oil change Is oil consumption excessive T Yes T No Visual Inspection Section 7 3 6 Engine Mounted Accessories Operational Check Section 7 3 5 Paper Induction Filter Replacement Section 7 3 5 Accessory M...

Page 152: ...mplete the 500 hour inspection according to the instructions in the Maintenance Manual heeding all warnings cautions and notes Initial the column beside the procedure upon completion Note any discrepancies in the Inspector Comments column Inspection Item Initials Inspector Comments 7 60 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 Throttle Position Switch Inspection Section 7 3...

Page 153: ...ce Manual heeding all warnings cautions and notes Place a check mark in the block to indicate completion of the inspection on each cylinder Note discrepancies in the Inspector Comments column Complete a visual inspection of the cylinder exterior and power stroke areas for signs of cracks leaks rust or pitting Section 7 3 7 1 Cylinders 1 2 3 4 T T T T Complete a visual inspection of the cylinder he...

Page 154: ...n inch T T T T Pitting of on cylinder wall T T T T Heavy wear T T T T Scoring T T T T Static seal leakage T T T T Other discrepancies T T T T Cylinder Inspection Summary Place a check mark in the column of any cylinder exhibiting the characteristics described in the left column Cylinders exhibiting the following characteristics must be removed and repaired or replaced according to the instructions...

Page 155: ...___ Engine in Storage ________ Date Inspection Performed ________ Inspection Performed by _____________________ Condition 1 2 3 4 Heavy bore wear T T T T Cylinder leaks T T T T Low differential pressure excessive oil consumption T T T T T T T T Static seal leakage head to barrel leakage or crack in head or barrel T T T T Inspection Follow up Check all column s that apply to the scope of inspection...

Page 156: ...Maintenance Inspections Teledyne Continental Motors Inc TM 7 64 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 This Page Intentionally Left Blank ...

Page 157: ...nifold Air Temperature Sensor 8 18 8 6 8 Cylinder Head Temperature CHT Sensor 8 19 8 6 9 Exhaust Gas Temperature EGT Sensor 8 20 8 6 10 Engine Diagnostic Interface 8 21 8 7 Starter System 8 22 8 8 Ignition System 8 23 8 8 1 Ignition Harness and Spark Plug Diagnostics 8 24 8 9 Lubrication System 8 25 8 10 Engine Cylinders 8 27 8 11 Crankcase or Accessory Case 8 28 8 11 1 Excessive Crankcase Pressur...

Page 158: ... 8 31 Figure 8 4 P1 and P2 50 pin connectors 8 35 Figure 8 5 P 3 and 4 25 pin connectors 8 35 Figure 8 6 P9 10 11 and 12 6 pin connectors 8 35 Figure 8 7 IOF 240 Electronic Control Unit 1 8 37 Figure 8 8 IOF 240 Electronic Control Unit 2 8 38 Figure 8 9 IOF 240 Fuel Control 8 39 Figure 8 10 IOF 240 Pressure Sensors 8 40 Figure 8 11 IOF 240 Temperature Sensors 8 41 Figure 8 12 IOF 240 Speed Sensor ...

Page 159: ...cording to specifications FADEC engines incorporate enhanced diagnostic capabilities A technician with a personal computer PowerLink FADEC Level I Diagnostic software and an interface cable can monitor sensor status and Electronic Control Unit activity from the aircraft cabin throughout the Engine Operational Check The Level I Diagnostic may also be used to validate the engine gauges If the option...

Page 160: ...n 8 11 1 Check circuit breakers and switch positions Primary Power C B Secondary Power C B Primary Power Switch Secondary Power Switch Master Power Switch BPMS Fuel Selector Valve Check Battery condition Check Fuel Level in tanks Starter turns when ignition switch is engaged OK OK Circuit breakers close switches positioned properly Go to Section 8 7 NOT OK Correct input conditions and retry NOT OK...

Page 161: ... filter NOT OK OK Check for induction system obstruction Correct IAW airframe manufacturer s instructions NOT OK Check propeller for imbalance Correct IAW propeller manufacturer s instructions Check for loose or broken engine mounts OK OK OK NOT OK Go to Section 8 6 Replace engine mounts NOT OK OK IOF 240 Series Engine Maintenance Manual 8 5 31 August 2007 Change 1 ...

Page 162: ...critical altitude See Engine Lacks Power or Maximum Manifold Pressure Reduced High oil temperature See Engine Will Not Run At Idle Speed Engine Will Not Run at Idle Speed Inspect induction system for leaks or loose connections Torque connections IAW Appendix B Adjust fuel system IAW Chapter 9 OK NOT OK 8 6 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 163: ...ication Correct input conditions and retry NOT OK Perform FADEC Level I Diagnostic Sect 8 6 1 Refer to Section 8 6 2 Perform Fuel Injector Operational Check Sec 8 4 1 NOT OK OK Master Power Switch ON FADEC Pri Power Switch ON FADEC Sec Power Switch ON Ignition Switch BOTH START BPMS AUTO OK Boost Pump activates and fuel pressure increases YES Refer to Aircraft Maintenance Manual for Fuel Pump Trou...

Page 164: ...Troubleshooting Teledyne Continental Motors Inc TM 8 4 1 Fuel Injector Operational Check 8 8 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 165: ...l Motors Inc TM Troubleshooting TM Troubleshooting Teledyne Continental Motors Inc IOF 240 Series Engine Maintenance Manual 8 9 31 August 2007 Change 1 IOF 240 Series Engine Maintenance Manual 8 9 31 August 2007 Change 1 ...

Page 166: ...istory from engine start to engine shutdown until the removable EDI memory is filled to capacity The EDI faceplate incorporates a 2 5mm stereo jack interface The EDI is a cabin mounted component usually beneath the instrument panel Consult the Aircraft Maintenance Manual for the EDI location If no EDI is installed the interface cable may be connected to the cabin harness EDI connector Without an E...

Page 167: ...profiles As test sequences increment the software records the data During engine operation the diagnostic software monitors and displays the engine operational status in comparison to the expected results On screen displays are color coded to identify pass fail status at a glance At the completion of the test sequence the Level I Diagnostic software compiles a report of the diagnostic test for on ...

Page 168: ...Troubleshooting Teledyne Continental Motors Inc TM 8 6 1 1 FADEC Power On Fault Isolation 8 12 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 169: ... following sensors Two Intake Manifold Air Temperature Sensors Sensor 1 Odd numbered control channels Sensor 2 Even numbered control channels Two Intake Manifold Air Pressure Sensors Sensor Connector P11 Odd numbered control channels Sensor Connector P12 Even numbered control channels Two Fuel Pressure Sensors Sensor Connector P9 Channels 1 and 4 Sensor Connector P10 Channels 2 and 3 Speed Sensor ...

Page 170: ...Troubleshooting Teledyne Continental Motors Inc TM 8 6 3 Electronic Control Unit ECU 8 14 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 171: ...Teledyne Continental Motors Inc TM Troubleshooting 8 6 4 Speed Sensor Assembly IOF 240 Series Engine Maintenance Manual 8 15 31 August 2007 Change 1 ...

Page 172: ...nostic Section 8 6 1 or Engine Operational Check Sect 6 1 NOT OK OK Secure the engine low voltage harness Perform FADEC Level I Diagnostic Section 8 6 1 or Engine Operational Check Sect 6 1 Replace ECU Section 10 11 Repair wiring Sect 10 10 OK NOT OK Master Power Switch ON FADEC Primary Power ON FADEC Secondary Power ON Check voltage between pins 5 0 0 05 VDC A and C D and F Disconnect P1 and P2 M...

Page 173: ...n 8 6 1 or Engine Operational Check Sect 6 1 NOT OK OK Secure the engine low voltage harness Perform FADEC Level I Diagnostic Section 8 6 1 or Engine Operational Check Sect 6 1 Replace ECU Section 10 11 Repair wiring Sect 10 10 OK NOT OK Master Power Switch ON FADEC Primary Power ON FADEC Secondary Power ON Check voltage between pins 5 0 0 05 VDC A and C D and F Disconnect P1 and P2 Master Power S...

Page 174: ... Temperature MAT sensors hard wired to the engine low voltage harness are secured in the throttle body with compression fittings The sensing element is a thermistor which changes resistance with temperature in a linear repeatable manner 8 18 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 175: ...ADEC Level I Diagnostic Section 8 6 1 or Engine Operational Check Sect 6 1 Replace ECU Sect 10 11 3 and 10 11 4 NOTE Allow the sensor to cool to ambient temperature prior to resistance measurements Apply heat to the CHT sensor tip with a heat gun while monitoring the sensor resistance Cut the sensor lead wire near the sensor to allow for splicing Verify the inner conductor is not touching the oute...

Page 176: ... sensor allow a 2 pigtail for splicing Verify the inner conductor does not touch the outer shield Measure resistance at the faulty circuit NO CHANGE VOLTAGE DECREASES Replace EGT sensor Sect 10 11 17 and 10 11 18 Wiring fault Use schematic diagrams and DVM to locate damaged wires Repair wiring 10 10 Open circuit Resistance at or near 0 Remove suspected faulty EGT sensor from the exhaust system All...

Page 177: ...Teledyne Continental Motors Inc TM Troubleshooting 8 6 10 Engine Diagnostic Interface IOF 240 Series Engine Maintenance Manual 8 21 31 August 2007 Change 1 ...

Page 178: ...ing to airframe manufacturer s instructions Engine Will Not Start When Ignition Switch Engaged Repair wiring IAW airframe manufacturer s instructions NOT OK Starter motor turns NOT OK Engine turns with starter OK Replace starter OK Replace starter NOT OK 8 22 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 179: ...ies Engine Maintenance Manual 8 23 31 August 2007 Change 1 Check ignition harness connections Engine Runs Rough Connect ignition harness properly Section 9 4 Ignition System Maintenance NOT OK Check spark plug condition Section 9 4 Perform FADEC Level I Diagnostic Sect 8 6 1 Refer to Section 8 6 2 NOT OK Replace faulty spark plugs Section 9 4 Ignition System Maintenance NOT OK Perform Ignition Har...

Page 180: ...odes are visible 5 Master Power Switch ON 6 Ignition Switch START Monitor spark plug electrodes for normal spark NOT OK Temporarily connect serviceable spark plugs to suspect high voltage leads repeat steps 5 and 6 Replace faulty high voltage leads Replace faulty spark plugs Replace ECU OK NOT OK NOT OK OK Perform Engine Operational Check Temporarily replace suspected high voltage lead wires in pa...

Page 181: ...K OK OK NOT OK High Oil Temperature Indication Check engine oil level Service oil sump to proper level with correct grade of aviation engine oil Reinstall original gauge Check engine oil temperature control valve operation Temporarily install a serviceable oil temperature gauge and recheck oil temperature Check engine oil pressure NOT OK OK Check oil pressure relief valve operation LOW NORMAL Repl...

Page 182: ...Troubleshooting Teledyne Continental Motors Inc TM 8 26 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 183: ...elines section in Chapter 9 Overhaul Inspection and Repair in the Engine Overhaul Manual OH 22 Low Compression See Rough Idling Excessive Oil Consumption See Rough Idling Excessive Crankcase Pressure See Section 8 11 1 Excessive Crankcase Pressure Sluggish operation See Rough Idling Continuous missing at high speed See Rough Idling Rough Idling Perform Cylinder Differential Pressure Check Proceed ...

Page 184: ...Troubleshooting Teledyne Continental Motors Inc TM 8 11 Crankcase or Accessory Case 8 28 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 185: ...oting 8 11 1 Excessive Crankcase Pressure 8 12 Exhaust System The IOF 240 Exhaust System is an airframe component Refer to the airframe manufacturer s troubleshooting procedures IOF 240 Series Engine Maintenance Manual 8 29 31 August 2007 Change 1 ...

Page 186: ...5 Use a Digital Volt ohm Meter DVM to measure between aircraft ground and the pins designated in the connector J5 Figure 8 2 and J6 Figure 8 3 pin layout tables Table 8 2 Connector Resistance Readings Plug Pin Label Resistance P5 or P6 B Ground 0 5 P5 or P6 D Ground 0 5 P5 or P6 J Enable A 0 5 P5 or P6 K Enable B 0 5 P5 or P6 S Ground 0 5 P5 or P6 V Ground 0 5 Figure 8 2 Pin Connector Layout for J...

Page 187: ...wer Power A L NC B Ground M NC C Secondary Power Power B N Boost Request D Ground P NC E RS485A R Primary Power Power A F RS485B S Ground G Fault 3 T NC H Fault 4 U Primary Power Power A J Enable 3 V Ground K Enable 4 NC Not Connected IOF 240 Series Engine Maintenance Manual 8 31 31 August 2007 Change 1 ...

Page 188: ...D J6 Resistance Readings Plug Pin Label Resistance P5 J Enable 1 0 5 P5 K Enable 2 OPEN P6 J Enable 3 0 5 P6 K Enable 4 OPEN 3 Ignition Switch R 4 Check resistance at the following pins J5 AND J6 Resistance Readings Plug Pin Label Resistance P5 J Enable 1 OPEN P5 K Enable 2 0 5 P6 J Enable 3 OPEN P6 K Enable 4 0 5 5 Ignition Switch BOTH 6 Check resistance at the following pins J5 AND J6 Resistance...

Page 189: ...P6 C Secondary Power Power B 1 P6 R Secondary Power Power B 1 P6 U Secondary Power Power B 1 IOF 240 Series Engine Maintenance Manual 8 33 31 August 2007 Change 1 7 FADEC Primary Power Switch OFF 8 Master Power Switch OFF 9 FADEC Secondary Power circuit breakers IN 10 HSA SSA Secondary Power circuit breakers IN 11 FADEC Secondary Power Switch ON 12 Measure the voltage with a DVM at the specified p...

Page 190: ...rframe ground the boost pump should stop NOTE The uninsulated end of the pin test lead wire will be electrically energized while conducting this test Use care to prevent the lead end from coming in contact with conductive items that could be damaged by electrical current 5 Insert one pin test lead in pin N Fuel Pump of J6 Connect the opposite end of the pin test lead to an airframe ground Listen f...

Page 191: ...cs 8 14 1 Connector Layout 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Figure 8 4 P1 and P2 50 pin connectors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Figure 8 5 P 3 and 4 25 pin connectors Figure 8 6 P9 10 11 and 12 6 pin connectors IOF 240 Series Engine Maintenance Manual 8 3...

Page 192: ...Troubleshooting Teledyne Continental Motors Inc TM 8 14 2 Schematic Symbol Legend 8 36 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 193: ...Teledyne Continental Motors Inc TM Troubleshooting Teledyne Continental Motors Inc TM Figure 8 7 IOF 240 Electronic Control Unit 1 IOF 240 Series Engine Maintenance Manual 8 37 31 August 2007 Change 1 ...

Page 194: ...Troubleshooting Teledyne Continental Motors Inc TM Teledyne Continental Motors Inc TM Figure 8 8 IOF 240 Electronic Control Unit 2 8 38 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 195: ...Teledyne Continental Motors Inc TM Troubleshooting Teledyne Continental Motors Inc TM Figure 8 9 IOF 240 Fuel Control IOF 240 Series Engine Maintenance Manual 8 39 31 August 2007 Change 1 ...

Page 196: ...Troubleshooting Teledyne Continental Motors Inc TM Teledyne Continental Motors Inc TM Figure 8 10 IOF 240 Pressure Sensors 8 40 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 ...

Page 197: ...2_TEXH_3_HI ECU2_TEXH_3_LO EGT 3 Ch Al P1 24 P1 40 ECU1_TEXH_2_HI ECU1_TEXH_2_LO EGT 2 Temperature Sensors 4 CYL FADEC REV D3 Page 5 of 7 Teledyne Continental Motors Inc TM P1 43 P1 32 P2 32 P2 43 Manifold Temperature 2 ECU2_TMAN_A_SIG ECU2_TMAN_A_RTN RED AWG22 WHITE AWG22 BLUE AWG22 WHITE AWG22 ECU1_TMAN_B_SIG ECU1_TMAN_B_RTN ECU2_TMAN_A_SIG ECU2_TMAN_A_RTN RED AWG22 BLUE AWG22 WHITE AWG22 WHITE ...

Page 198: ...Troubleshooting Teledyne Continental Motors Inc TM 8 42 IOF 240 Series Engine Maintenance Manual Teledyne Continental Motors Inc TM Figure 8 12 IOF 240 Speed Sensor Assembly Change 1 31 August 2007 ...

Page 199: ...2 WOT_LAMP FUEL_PUMP POWER_A POWER_A GND_A GND_A GND A B C D E F G H J K L M N P R S T U V P2 1 P2 34 P2 38 P2 22 P2 20 P2 36 P2 21 P2 37 P2 19 P4 12 P4 25 P3 12 P3 25 ECU2_POWER_A GND ECU2_RS485_A ECU2_RS485_B ECU2_FAULT_3 ECU2_FAULT_4 ECU2_ENABLE_3 ECU2_ENABLE_4 ECU2_FUEL_RELAY SSA_POWER_B SSA_POWER_B SSA_GND_B SSA_GND_B POWER_A GND RS485_A RS485_B FAULT_3 FAULT_4 ENABLE_3 ENABLE_4 FUEL_PUMP POW...

Page 200: ...Troubleshooting Teledyne Continental Motors Inc TM 8 44 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 This Page Intentionally Left Blank ...

Page 201: ...13 9 4 2 Ignition Harness Installation 9 15 9 5 Adjustment Procedures 9 17 9 5 1 Throttle Position Switch Adjustment 9 17 9 5 2 Fuel System Adjustment 9 20 LIST OF TABLES Table 9 1 Cleaning Guidelines for Aircraft Engine Parts 9 2 Table 9 2 Cleaning Tips 9 3 Table 9 3 Painting External Parts 9 7 Table 9 4 Approved Spark Plug List 9 14 LIST OF FIGURES Figure 9 1 Ground Straps and Connection Points ...

Page 202: ... Plug manufacturer s recommendations Remove inspect clean and gap spark plugs per spark plug manufacturer s instructions Ensure each spark plug is free of any residue Connectors CR4 or equivalent electrical contact cleaner Do not use water base or petroleum base solvent to clean connectors If a cleaning fluid is suspected to have entered a connector blow the excess away from the connector and plac...

Page 203: ...ngine or its parts Gasoline Kerosene Abrasive cleaning paste Cleaning powder Dispose of cleaning solvents in accordance with Environmental Protection Agency EPA regulations Do not scrape parts or use wire brushes sandpaper abrasive cloth or abrasive wheels to clean or polish parts to prevent concentrated stress to scratched areas and fatigue failure Dry blast only with plastic media or natural mat...

Page 204: ...rate the high levels of Electro Magnetic Interference EMI and lightning that may be experienced in the flight environment Any ground straps electrical connectors electrical terminals and shields that are loose corroded or broken must be repaired or replaced prior to further flight operations Ground points Ground straps Ground points Ground straps Figure 9 1 Ground Straps and Connection Points 1 Re...

Page 205: ... holes to prevent formation of foaming emulsion in the engine oil on re assembly If not removed completely the alkaline residue can corrode the part When utilizing compressed air wear OSHA approved safety glasses goggles or faceshield Never exceed 30 psi when using compressed gases for cleaning purposes OSHA 1910 242 b 4 Dry the part with a jet of dry compressed air 5 If the carbon deposits still ...

Page 206: ...l parts that have areas of worn paint as described in the section Applying Paint to Engine Parts 9 2 1 Alodine Apply a protective coating of alodine under any of the following conditions Parts with aluminum surfaces that have been cleaned machined or repaired Aluminum alloy castings Sheet metal Aluminum or metal tubing If the original aluminum conversion coating has been removed or deteriorated it...

Page 207: ...ly primer or enamel paint to internal engine parts or any part that has direct contact with engine oil The paint or primer may flake or break off during engine operation and contaminate engine oil Table 9 3 Painting External Parts Aluminum Parts Ferrous Parts Magnesium Parts Apply alodine to the part as described in the Alodine section Apply enamel to the part Apply zinc chromate primer Apply enam...

Page 208: ... is suspect investigate for oil leakage If no oil leakage is noted perform a Cylinder Inspection in Chapter 7 Maintenance Inspections in this manual Petroleum based aviation engine oil is flammable Follow all fire hazard precautions Store the oil in a well ventilated area away from any heat or ignition source When adding oil completely remove the protective seal on the oil container to prevent the...

Page 209: ...d dipstick 2 Wipe the rod clean with a clean lint free cloth 3 Insert the oil gauge rod back into the oil sump and withdraw the rod again 4 Verify the oil level touches but does not pass the fill line on the rod CAUTION Do not overfill the oil sump 5 If more oil is required add a sufficient quantity of the oil specified to reach the fill line on the oil gauge rod Oil Cap Oil Filler Neck Air Oil Se...

Page 210: ...al suspended in the oil Wear material consists of submicroscopic particles due to frictional loading that occurs during engine operation Refer to section 9 3 4 Oil Trend Monitoring and Spectrographic Oil Analysis 2 Reinstall the drain plug with a new crush gasket torque according to Appendix B specifications and safety wire the plug according to Appendix C instructions 3 Remove the oil filter Figu...

Page 211: ...er This analysis is done starting with the first oil change sample and continues with successive oil changes The first few samples establish a baseline subsequent samples at least three taken over time establish engine wear trends These trends help determine if wear material is deviating from the normal baseline Establishment of the baseline and ensuing wear trends assume that the analyses are bei...

Page 212: ...evices a Sampling tube and or funnel b Sample vial NOTE The sampling tube funnel and sample vial must be clean and free of any debris foreign material or residue for sample integrity and accurate analysis 3 Collect 1 to 2 ounces 30 to 60 ml of oil from one of the following sample collection locations consistently a Midstream of the oil drain flow after 1 3 of the oil has been drained from the oil ...

Page 213: ...N NORMAL WORN OUT CONDITION SEVERE WORN OUT CONDITION ELECTRODES ERODED BY HIGH VOLTAGE SPARKING AND BY CORROSIVE GASES FORMED DURING COMBUSTION TO LESS THAN 1 2 ORIGINAL THICKNESS MORE VOLTAGE NEEDED TO FIRE SPARK PLUGS OFTEN MORE THAN IGNITION SYSTEM CAN PRODUCE REPLACE WITH NEW APPROVED AVIATION SPARK PLUGS EXCESSIVELY ERODED CENTER AND GROUND ELECTRODES PLUS EXTENSIVE NECKING OF FINE WIRE GROU...

Page 214: ... may result in incomplete sealing of the combustion chamber loss of spark plug heat transfer spark plug overheating possible re ignition detonation and internal engine damage 7 Install a new copper gasket on all 8 spark plugs 8 Refer to the spark plug rotation chart Figure 9 4 mark serviceable spark plugs with the respective destination positions For all remaining locations replace with a new spar...

Page 215: ...ltage harness to the spark plugs until propeller installation is completed Failure to comply can result in bodily injury when the propeller is rotated during installation Procedure 1 Route the ECU end of the ignition lead wires to the appropriate ECU Each ignition lead wire has a metal identification ID tag that designates the cylinder and spark plug assignment For example 2T designates the lead i...

Page 216: ...ower threads turn the B nut clockwise d Restrain the lead wire ferrule to prevent kinking of the lead e Continue rotating the B nut until it seats f Torque the B nut per Appendix B CAUTION Do not allow the ignition lead wire ferrule to twist while tightening the B nut If twisting is observed hold the knurled portion of the B nut shoulder with a wrench while tightening the B nut 6 Route leads as fa...

Page 217: ...instructions NOTE Before performing any engine fuel system adjustment or setup procedures verify the aircraft fuel system and fuel pump are operating properly in accordance with the airframe manufacturer s instructions and perform the Engine Operational Check in Chapter 6 Operational Performance Checks 9 5 1 Throttle Position Switch Adjustment Procedure 1 Loosen the TPS securing screw Figure 9 8 A...

Page 218: ...ten the pivot screw and remove the feeler gauge 8 Close the throttle and return it to the WIDE OPEN position Check the distance 0 003 inches between the back of the TPS actuator and the TPS housing with the feeler gauge Repeat the adjustment if required 9 Place the aircraft Master Power Switch FADEC Primary and Secondary Power Switches in the ON position 10 Cycle the throttle from OPEN to CLOSED p...

Page 219: ...0 32 25 32 50 32 75 33 00 33 25 33 50 33 75 34 00 34 25 34 50 34 75 35 00 35 25 35 50 35 75 36 00 1975 2000 2025 2050 2075 2100 2125 2150 2175 2200 2225 2250 2275 2300 2325 2350 2375 2400 2425 2450 2475 2500 2525 Engine Speed RPM Fuel Pressure PSIG Figure 9 9 Fuel Pressure vs Engine Speed Chart IOF 240 Series Engine Maintenance Manual 9 19 31 August 2007 Change 1 ...

Page 220: ... Check 2 Loosen the lock nut on the Idle Fuel Pressure Relief Valve Assembly located at the rear of the fuel pump See Figure 9 10 3 Adjust relief valve clockwise to increase idle fuel pump pressure or counter clockwise to decrease idle fuel pump pressure NOTE Operate the engine at 1500 1800 RPM for 15 seconds after each adjustment Retard the throttle to the specified IDLE RPM to obtain an accurate...

Page 221: ...ment clockwise to increase pressure and counterclockwise to decrease pressure Recheck IDLE RPM pump pressure and adjust if necessary 7 Repeat the operational check and adjustments until idle and full power RPM are within limits 8 If fuel pressure settings are correct torque jam nut on the orifice adjustment to Appendix B specifications 9 Adjust the IDLE RPM Figure 9 11 to 850 25 RPM for propeller ...

Page 222: ...st pump is operating If leaks are detected recheck and torque leaking connections If leaks persist remove and inspect fittings replace faulty fittings 17 BPMS OFF 18 Ignition Switch OFF 19 FADEC Secondary Power Switch OFF 20 FADEC Primary Power Switch OFF 21 Master Power Switch OFF 22 Perform a visual inspection of the engine compartment Install the engine cowling according to the airframe manufac...

Page 223: ...ir and Replacement 10 17 10 5 3 Oil Cooler Removal and Replacement 10 18 10 5 4 Oil Cooler Filter Adapter Installation 10 21 10 5 5 Oil Temperature Control Valve Inspection and Replacement 10 22 10 5 6 Lubrication Component Service Limits 10 23 10 6 Engine Cylinder Maintenance 10 24 10 6 1 Engine Cylinder Removal 10 24 10 6 2 Piston Cleaning 10 28 10 6 3 Engine Cylinder Dimensional Inspection 10 2...

Page 224: ...allation 10 71 10 11 16 Manifold Air Temperature MAT Sensor Removal 10 73 10 11 17 Manifold Air Temperature MAT Sensor Installation 10 73 10 11 18 Exhaust Gas Temperature Sensor Removal 10 74 10 11 19 Exhaust Gas Temperature Sensor Installation 10 75 10 11 20 Cylinder Head Temperature CHT Sensor Removal 10 75 10 11 21 Cylinder Head Temperature CHT Sensor Installation 10 75 10 11 22 Five Lamp HSA R...

Page 225: ... Screws on Front of Crankcase 10 40 Figure 10 22 Crankshaft Nose Oil Seal Parts 10 41 Figure 10 23 Crankcase Critical Non Shaded and Non Critical Shaded Areas 10 43 Figure 10 24 Crankcase Breather Installation 10 43 Figure 10 25 EGT wire repair pins mated to wires 10 46 Figure 10 26 Stripping the Overbraid Jacket 10 47 Figure 10 27 Shield Stripping of EGT Sensor Wire 10 47 Figure 10 28 Inner Jacke...

Page 226: ... Fuel Injector 10 68 Figure 10 58 Manifold Air Pressure Sensor 10 70 Figure 10 59 Harness Connector and Sensor Orientation Keys 10 71 Figure 10 60 Manifold Air Temperature Sensor 10 73 Figure 10 61 Marking the MAT Sensor 10 73 Figure 10 62 EGT Sensor Installation 10 75 Figure 10 63 Multi Channel HSA Connections 10 75 Figure 10 64 Throttle Position Switch Fasteners 10 75 Figure 10 65 Throttle Posit...

Page 227: ...ection apply only to maintenance procedures and in many cases are not identical to the more stringent new part tolerances in Appendix D of the Overhaul Manual Table 10 1 Parts Handling Guidelines Part Components Handling Instructions Wrapped new or rebuilt parts Parts that require protection from atmospheric dust and moisture should be wrapped or boxed after they are inspected acceptance inspectio...

Page 228: ...d Installation Crankcase Cylinder Deck Stud Replacement Crankcase helical coils Appendix C In Chapter 9 of the Overhaul Manual OH 22 refer to Crankcase Cylinder Deck Stud Helical Coil Installation Starter Starter Replacement in Section 10 3 Alternator Alternator Replacement in Section 10 4 Oil pump Oil Pump or Tach Drive Repair and Replacement in Section 10 5 1 Oil filter Engine Oil Servicing in C...

Page 229: ...taching hardware and gasket discard the gasket 4 Inspect the fuel pump drive coupling IAW the Fuel Pump Drive Coupling Service Limits in Table 10 4 Replace parts which do not meet service limit specifications 1 3 2 4 8 5 6 7 Figure 10 1 Fuel Pump Drive Coupling Table 10 4 Fuel Pump Drive Coupling Fits Limits Item No Figure 10 1 Description Service Limits inches 1 Fuel pump adapter pilot in crankca...

Page 230: ...ump drive coupling 29 in the fuel pump 5 Apply a thin translucent coat of Gasket Maker to the mating surface of the crankcase and new gasket 15 Install a new gasket 15 on the fuel pump 15 6 Lubricate the fuel pump cavity with clean 50 weight aviation engine oil 7 Install the fuel pump 2 on the crankcase with washers 7 new lock washers 8 and nuts 9 Torque the fastening nuts 9 per Appendix B 8 Conne...

Page 231: ...th the airframe manufacturer s instructions 3 Remove the bolt Figure 10 3 7 lock washer 4 and washers 6 from the rear of the accessory case and the rear engine lifting eye Discard the lock washers 4 Remove three sets of nuts 5 lock washer 4 washers 3 and spacers 8 from the starter mounting flange Carefully remove the starter motor assembly without damaging the mounting stud threads Discard the loc...

Page 232: ...g surface of the accessory case and new gasket 1 Figure 10 3 CAUTION Apply the Gasket Maker sparingly to prevent contaminating the engine oil system 3 Install the new gasket 1 on the accessory case 4 Install the following hardware on the accessory case rear lifting eye and starter motor a Bolt 7 b New lock washers 4 c Washers 6 d Nut 5 e Washer 3 f Spacer 8 5 Torque the mounting hardware according...

Page 233: ...Teledyne Continental Motors Inc TM Non Overhaul Removal and Replacement IOF 240 Series Engine Maintenance Manual 10 11 31 August 2007 Change 1 Lifting Eye Lifting Eye Figure 10 3 repeated for reference ...

Page 234: ...ng maintenance Do not stand or place equipment within the arc of the propeller 1 Refer to Figure 10 4 remove the electrical connections from the alternator according to the aircraft maintenance manual 2 Remove three lock nuts 14 and washers 13 and the tach drive adapter cover 12 discard the lock nuts 13 3 Remove three lock nuts and washers 2 3 4 Remove the alternator 4 from the crankcase 5 Remove ...

Page 235: ... pin does not align gradually increase torque to align the castellated nut with the cotter pin hole If alignment cannot be achieved within the torque limits replace the nut 6 Do not over torque 8 Install a new cotter pin 7 and secure it in accordance with Appendix C instructions 9 Install a new gasket 1 10 4 3 Direct Drive Alternator Installation Procedure 1 Perform a Gear Tooth Inspection on the ...

Page 236: ...ove the bolt washer and lock washer on the alternator adjusting bracket 2 Remove the alternator drive belt 3 Remove the pivot bolt 4 Refer to Figure 10 6 remove the bolts nuts and washers to remove the alternator mounting bracket 5 Dismantle and repair the belt driven alternator in accordance Kelly Aerospace ES 1010 Alternator Maintenance and Overhaul Manual 10 4 5 Belt Driven Alternator Installat...

Page 237: ... ADJUSTING BRACKET BOLT WASHER LOCKWASHER ALTERNATOR PIVOT BOLT ALTERNATOR DRIVE BELT SCREW DRIVE SHEAVE NUT WASHER ALTERNATOR BRACKET WASHER NUT NUT SPLIT SHEAVE SPACER WASHER Figure 10 5 Front View of Belt Driven Alternator ADJUSTING BRACKET DRIVE SHEAVE NUT WASHERS BOLT LOCK WASHER BOLT MOUNTING BRACKET Figure 10 6 Side View of Belt Driven Alternator ...

Page 238: ... from the airframe 1 Disconnect electrical power to the engine and ensure the Ignition Switch is turned OFF 2 For the tach drive adapter replacement refer to the Accessory Case Removal and Installation instructions in Chapters 6 and 11 respectively in the TCM Overhaul Manual OH 22 3 Remove malfunctioning oil pumps or oil pump components by removing the oil pump according to the Oil Pump Removal in...

Page 239: ...gine NOTE Secure the Speed sensor assembly according to the instructions in Section 6 of the Overhaul Manual while the Oil Sump is removed 2 Replace the oil sump following the Oil Sump Removal instructions in Chapter 6 of the TCM Overhaul Manual OH 22 and install a new oil sump as instructed in the Oil Sump Installation in Chapter 11 of the TCM Overhaul Manual OH 22 3 The oil suction tube to the o...

Page 240: ...he propeller NOTE Remove and replace the oil cooler according to the airframe manufacturer s instructions 10 5 3 1 Oil Cooler Adapter Removal Procedure 1 Drain the engine oil according to instructions in Chapter 9 Engine Oil Servicing 2 Refer to Figure 10 8 remove the adapter fittings 4 from the oil cooler adapter 3 Remove the O rings 3 from the fittings 4 discard the O rings 3 4 Cut remove and di...

Page 241: ...s 11 Torque the nuts 11 per Appendix B 2 Install the fittings 4 with new o rings 3 and torque according to Appendix B 3 Install the oil temperature control valve with a gasket and torque according to Appendix B Safety wire the valve according to Appendix C 4 Service the engine with fresh oil see Engine Oil Servicing in Chapter 9 Figure 10 8 Oil Cooler Adapter 1 Gasket 7 Plain Washer 2 Oil Cooler A...

Page 242: ...re 12 on the Oil Temperature Control Valve 6 7 Remove the Oil Temperature Control Valve from the oil cooler filter adapter 2 8 Remove the gasket 5 from the Oil Temperature Control Valve 6 and discard the gasket 5 9 Remove the attaching hardware 7 through 11 Discard the lock washers 8 10 Remove the oil cooler filter adapter 2 from the crankcase 11 Remove the gasket 1 from crankcase and discard the ...

Page 243: ...k washers 8 plain nuts 9 washers 10 and nuts 11 Torque the nuts 11 per Appendix B 2 Install the oil temperature control valve 6 with a new gasket 5 and torque according to Appendix B Safety wire the valve according to Appendix C 3 Install the two oil cooler hose fittings 4 14 with new o rings 3 torque according to Appendix B specifications 4 Install a new oil filter Torque the filter 13 per Append...

Page 244: ...ol valve 4 Inspect the conical valve seat Figure 10 10 of the oil temperature control valve for scoring and nicks If the valve is nicked or scored replace the valve 5 Visually inspect the seat in the oil cooler adapter for scoring nicks or debris If damage is evident resurface the seat or replace the oil cooler adapter according to instructions in section 10 5 3 6 Apply Anti Seize Lubricant to the...

Page 245: ... Item No Figure 10 11 Description Service Tolerances inches Maximum 1 Oil pump gears in housing end clearance 0 0070L 2 Oil pump gears in housing diameter 0 0080L 3 Oil pump gear shafts in accessory case and plate diameter 0 0045L 4 Oil pump gear cavity diameter 1 501 5 Oil pump gear shaft diameter 0 5630 6 Oil pump gear cavity depth 0 8040 7 Square drive to camshaft gear clearance 0 0135L 8 Oil p...

Page 246: ...he battery in accordance with the airframe manufacturer s instructions 4 Disconnect all spark plug leads 5 Tag the propeller with the warning DO NOT TURN PROPELLER 6 Remove the Fuel Injection Ignition Induction and Exhaust System components in accordance with instructions in Chapter 6 Engine Disassembly in the overhaul manual and the applicable airframe manufacturer s instructions 7 While removing...

Page 247: ...ss Nut 48 Compression Ring 7 Stud 21 Bushing 35 Pushrod Housing 49 Compression Ring 8 Stud 22 Plug 36 Gasket 50 Oil Control Ring 9 Stud 23 Thrust Washer 37 Spring 51 Scraper Ring 10 Exhaust Seat Insert 24 Shaft 38 Washer 52 Piston Pin 11 Intake Seat Insert 25 Retainer 39 Packing 53 Piston 12 Exhaust Valve 26 Tab Washer 40 Pushrod 54 Check Valve 13 Intake Valve 27 Nut 41 Drain Tube 55 Bayonet adapt...

Page 248: ...g the other hand free to catch the piston as the cylinder is withdrawn to prevent damage to the crankcase or cylinder 22 Remove the cylinder base packing 1 Install the old packing in a figure 8 pattern Figure 10 13 to support the connecting rod Figure 10 13 Cylinder Base Packing Configuration on Connecting Rod Support 23 Remove the piston pin 52 Figure 10 12 and piston 53 from the connecting rod I...

Page 249: ...crapers to clean piston ring lands b Perform Fluorescent Penetrant and Magnetic Particle Inspections as described in Chapter 9 Inspection and Repair in the Overhaul Manual OH 22 c Perform a dimensional inspection on the cylinder the piston valve train and components as directed in the section Engine Cylinder Dimensional Inspection in Chapter 9 Inspection and Repair of the Overhaul Manual OH 22 usi...

Page 250: ...ype of media will become embedded in aluminum parts rendering them unusable 3 Clean the piston and cylinder bores with hot soapy water and a stiff bristled non wire scrub brush to remove all blasting materials from the piston Thoroughly rinse all soap residue from the piston and cylinder bore using hot water CAUTION Do not use wire brushes or scrapers of any kind to clean the piston 4 Clean the pi...

Page 251: ...lve guides The guide dimensions must meet specifications Replace worn or non conforming guides 6 Inspect the intake valve seats for any indication of burning pitting erosion or cracks Check the valve seat dimensions Inspect the outside length of the intake and exhaust valve stems using a micrometer Replace any valve that does not conform to the service limits or is cracked eroded burnt or pitted 7...

Page 252: ...S 22 32 25 6 Cylinder barrel in crankcase diameter 0 0110L 7 Intake valve seat insert in cylinder head diameter 0 0055T 8 Intake valve guide in cylinder head diameter 0 0010T 9 Exhaust valve guide in cylinder head diameter 0 0010T 10 Exhaust valve seat insert in cylinder head diameter 0 0070T 11 Intake valve seat width See Figure 10 16 12 Exhaust valve seat width See Figure 10 17 Exhaust valve sea...

Page 253: ... 042 33 Second ring gap at 1 00 50 depth in cylinder barrel gap Gap for second ring must be at least 006 larger than gap for top ring 0 048 34 Third ring gap at 1 00 50 depth in cylinder barrel gap 0 035 35 Fourth ring gap at 1 00 50 depth in cylinder barrel gap 0 031 36 Piston pin in piston diameter 0 0010L 37 Piston pin diameter 0 9984 Piston pin oversize diameter 0 005 1 0034 38 Piston pin in c...

Page 254: ...Non Overhaul Removal and Replacement Teledyne Continental Motors Inc TM 10 32 IOF 240 Series Engine Maintenance Manual 29 November 2006 Figure 10 14 IOF 240 Cylinder Assembly ...

Page 255: ... 4 447 4 439 4 441 4 446 4 448 4 436 4 438 015 4 452 4 454 4 455 4 457 4 449 4 451 4 456 4 458 4 446 4 448 Cylinder bore out of round new not to exceed 002 at measured diameters Service limit not to exceed 003 at measured diameters Table 10 8 Piston to Cylinder Clearance 4 44 inch PISTON PISTON BOTTOM OF SKIRT IN CYLINDER ALL NON MOLY COATED 0 006 0 010 LOOSE MOLY COATED 0 004 0 009 LOOSE Measure ...

Page 256: ...aul Removal and Replacement Teledyne Continental Motors Inc TM 10 34 IOF 240 Series Engine Maintenance Manual 29 November 2006 Figure 10 16 Intake Valve Seat Dimensions Figure 10 17 Exhaust Valve Seat Dimensions ...

Page 257: ...ccording to Piston Cleaning instructions in this section Perform fluorescent penetrant magnetic particle and dimensional inspections on specified cylinder and piston parts according to the TCM Overhaul Manual Chapter 9 Inspection and Repair Install acceptable hydraulic tappets in the same location from which they were removed Assemble cylinders that conform to inspection criteria and service limit...

Page 258: ...n 50 weight aviation engine oil 5 Install a conforming piston pin 53 with new piston rings 48 through 50 partially in the cylinder bore 6 When installing the connecting rod use care not to drop the connecting rod on the cylinder deck to avoid damaging the cylinder Carefully rotate the crankshaft placing the connecting rod of the cylinder being installed in the outer most position Remove the packin...

Page 259: ... on the push rod housing 15 Install the springs 39 washers 36 and push rod housing 35 16 Install the push rods 40 in their respective housings 35 17 Position the crankshaft so the piston is at top dead center and both intake and exhaust valves of the cylinder are closed 18 Check the distance between the retainers and rocker arms with a feeler gage Side Clearance should be between 0 005 and 0 035 F...

Page 260: ...cable airframe manufacturer s instructions 29 Set the aircraft Fuel Selector Valve to the ON position and activate the fuel boost pump to leak check the fuel delivery system including fuel lines and fittings 30 Install the aircraft cowling and airframe supplied accessories CAUTION Service the engine with SAEJ 1966 mineral oil for engine break in 31 Service the engine with mineral oil according to ...

Page 261: ...ged or if any of the following conditions exist Ram air is entering the engine interior indicated by excessive crankcase pressure Oil leaks from the nose seal or nose seal retainers 10 7 1 Crankshaft Nose Oil Seal Removal Procedure WARNING If engine electrical power is not disconnected a faulty ignition circuit could allow the engine to start and the propeller to rotate Do not stand or place equip...

Page 262: ...such as Loctite Chisel or methylene chloride followed by a naptha solvent such as Loctite ODC Free Cleaner and Degreaser Remove all residue and debris from the bore 9 Refer to the Crankshaft Overhaul section in Chapter 9 of the Overhaul Manual OH 22 for instructions on restoring the tin plating and helix pattern on the crankshaft at the crankshaft nose oil seal area 10 7 2 Crankshaft Nose Oil Seal...

Page 263: ...f Gasket Maker on the wall of the oil seal counterbore Refer to Gasket Maker application instructions in Appendix C 14 Using thumb pressure work the seal into the crankcase counterbore with the oil seal split line positioned at the 10 or 2 o clock position 15 After the seal is in place wipe any remaining oil from the seal and crankshaft 16 Spray the exposed portion of the lightly scratched criss c...

Page 264: ...ment Refer to the affected white areas in Figure 10 24 Any crack 1 inch 2 54 cm or more in length in the shaded non critical locations in Figure 10 24 requires repair or replacement of the crankcase Scribe cracks smaller than 1 inch in the non critical areas at the extremities for further growth progression monitoring Any crack with seeping oil must be repaired or replaced immediately At 25 hour i...

Page 265: ... Install the oil breather a Apply Lockquick Primer grade N to the breather flange and breather tube and allow them time to dry b Apply Loctite 271 to both the breather flange and breather tube c Install the breather to the appropriate height and orientation specified in Figure 10 25 Wipe excess Loctite from the crankcase d Connect the breather hose according to the Airframe manufacturer s instruct...

Page 266: ...itute faults in the engine low voltage harness and require lead wire repair or sensor replacement If engine low voltage harness sensors may be replaced and wires may be repaired with the instructions in Section 10 10 3 Non EGT Sensor and Lead Wire Replacement or sent to the factory or an authorized service center for repair EGT Sensor lead wires are K type thermocouples and have chromel and alumel...

Page 267: ...s ECUs The engine low voltage harness connects to the airframe at nineteen pin circular connectors The FADEC pressure sensors are circular six pin connectors The six 19 25 and 50 pin connectors are assembled with potting compound for strength and are not field reparable The low voltage 25 and 50 pin DIN connectors for the ECUs and Speed Sensor Assembly must be installed with EMI gaskets and enviro...

Page 268: ...the appropriate EGT Sensor Wire Splice kit from TCM The EGT splice kit will not work for non EGT sensors and the non EGT splice kit will work for EGT sensor wiring NOTE Refer to Figure 10 25 The EGT wires are alumel red and chromel yellow To maintain signal integrity all segments of the wire must be the same material The EGT splice kit contains an alumel green band pin and socket and a chromel whi...

Page 269: ...lit lead wire jacket should appear as shown in the photo in Figure 10 27 CAUTION When stripping the shield avoid nicking or cutting the insulation of the two conductors within the lead Figure 10 26 Stripping the Overbraid Jacket Figure 10 27 Shield Stripping of EGT Sensor Wire 8 Fold the split portion of the shield back 9 Use small shears to trim the braid at the mark at 1 5 8 from the end of the ...

Page 270: ...ire one inch shorter than the red wire 15 Strip both sensor wires 3 16 inch from their cut ends The prepared sensor lead should resemble Figure 10 30 1 inch 1 inch Figure 10 30 EGT Sensor Lead Preparation Complete 16 Repeat steps 5 15 to prepare the mating sensor wires in the same manner as the first pair except in step 14 cut the red sensor wire one inch shorter than the yellow wire 17 The prepar...

Page 271: ...trudes from the barrel of the pin Crimp the socket on the red wire Figure 10 32 Alumel wire with pins installed 22 Slide a 1 section of heat shrink tubing over the alumel green band pin Join the alumel pin and socket by inserting the pin into the socket until the pin seats in the socket Center the heat shrink tubing over the joined pin and socket ensuring the no metal is visible on either side of ...

Page 272: ... is visible on either side of the heat shrink tubing Apply heat to the heat shrink tubing to secure it over the joined connectors CAUTION Failure to use the appropriate splicing barrel for each EGT wire will result in abnormal engine operation and may cause engine damage Heat shrink tubing shrunk to splice No exposed conductors Heat shrink tubing shrunk to splice No exposed conductors Figure 10 35...

Page 273: ... C CAUTION Avoid making sharp bends or kinks in the lead wires 35 Perform a FADEC Level I Diagnostic according to instructions in Chapter 8 Troubleshooting 10 10 3 Non EGT Sensor and Lead Wire Replacement Equipment Required Crimp tool Non EGT Sensor Wire Splice Kit Utility or razor knife Scissors A variable intensity heat gun with a small deflector tip Prerequisites Before proceeding review Sectio...

Page 274: ... of the wire The wire should resemble Figure 10 38 Figure 10 37 Slice the Outer Shielding Figure 10 38 Split Outer Shielding CAUTION While stripping the wire shield avoid nicking or cutting the insulation of the two conductors within the lead 8 Trim the excess braided shielding to the two inch mark with the small shears 9 Carefully inspect the insulation of each wire for nicks or cuts If nicks or ...

Page 275: ...r Lead Wire 14 Repeat steps 5 through 13 for the mating end of the lead or sensor wires except in Step 12 cut the trace wire one inch shorter than the white wire 15 Consult the engine low voltage harness wiring diagrams in Chapter 8 Check the continuity of the wires under repair before installing a splice or new sensor If the resistance is greater than 500 ohms closer inspection of the harness seg...

Page 276: ...the work area of any oil or grease residue Cap or close all fuel sources Thoroughly dry any open fuel spill before using the hot air gun Shield components and wiring in proximity to the item being heated 18 Insert the two white wires in a solder sleeve overlapping the stripped ends of the two wires Center the middle band of the solder sleeve on the overlapped wires Figure 10 43 and evenly apply he...

Page 277: ...lock it in place Verify the CHT sensor is securely installed in bayonet adapter WARNING Failure to install the CHT Sensor on the correct cylinder will result in abnormal engine operation b Install the MAT sensors according to instructions in Section 10 11 17 Manifold Air Temperature MAT Sensor Installation c Install the fuel injector solenoid according to Section 10 11 11 Fuel Injection Solenoid I...

Page 278: ...ve the connector s firmly grasp the edges of the connector back shell and pull the connector away from the unit NOTE The engine low voltage harness connector fasteners are captive in the back shell and cannot be removed from the connector WARNING Do not separate the connector s from the unit by pulling on the harness leads Pulling on the harness leads can cause permanent irreparable damage to the ...

Page 279: ...to the header as the pin socket may fill with fluid Sparingly apply cleaner to cleaning cloth 7 Inspect the engine low voltage harness connector for contamination deformed pins or any observable discrepancies If the old seal is observed at the base of the connector pins remove with tweezers 8 Check the resistance between the connector s header Figure 10 48 and airframe electrical ground The resist...

Page 280: ...he EMI gaskets and allow 30 seconds for the adhesive to become tacky 14 Place the EMI gasket glue side down in position over the connector header with the notched edge of the gasket facing up Figure 10 49 and Figure 10 50 Notched Edge Sealant Strip EMI Gasket Notched Edge Sealant Strip EMI Gasket Figure 10 49 EMI Gasket and Seal where arrow is in Position on ECU Header Shell EMI Gasket Sealant Str...

Page 281: ...r Connector 10 11 2 Ground Strap Installation The IOF 240 has two ground wires installed between the airframe and each ECU one ground strap between the engine and the throttle body and another ground strap between the crankcase and the oil sump All ground straps must be in place and functional for proper FADEC system operation Procedure 1 Clean contact surface thoroughly with MEK or other mild sol...

Page 282: ...alfunction replace it with a serviceable unit Procedure 1 Disconnect electrical power to the engine and remove the high voltage ignition lead wires from the ECU Cut and remove cable ties as necessary to pull the leads clear of the ECU mounting area 2 Place protective covers over the threaded end of each of the ECU spark towers 3 Cut and remove cable ties from the engine low voltage harness stalk l...

Page 283: ...isconnect electrical power to the engine prepare the mounting location for the ECU per airframe instructions in the locations specified by the airframe original equipment manufacturer OEM or STC holder 2 Using a DVM check the resistance at the following locations a Between the 50 pin connector header shell and a bare metal point on the engine b Between the 50 pin connector header shell and the bod...

Page 284: ...esistance must be less than 0 5 ohms If the resistance is more than 0 5 ohms a Clean the mating surfaces and re measure the resistance b If resistance is still greater than 0 5 ohms find an alternate mounting location for the ground strap 6 Install the ground strap according to the instructions in section 10 11 2 Ground Strap Installation 7 Install the High Voltage Harness according to instruction...

Page 285: ...ashers nuts and hold down washers Figure 10 54 NOTE The Speed Sensor Array is sandwiched between the crankcase and the oil sump Most installations will require the engine to be removed in order the remove the oil sump Refer to Engine Removal in Chapter 5 of the Overhaul Manual OH 22 and Oil Sump Removal instructions in Chapter 6 of the Overhaul Manual No field repairs of the signal conditioner or ...

Page 286: ...down washers washers and nuts from SSA signal conditioner Remove the SSA signal conditioner from the accessory case 11 Temporarily secure the SSA signal conditioner near the lower left engine mount with a cable tie 12 Remove and discard the signal conditioner gasket from the accessory case 13 Drain the engine oil from the oil sump Chapter 9 Engine Oil Servicing 14 Follow the Engine Oil Sump Remova...

Page 287: ...are OFF 2 Disconnect the high voltage harness and remove the top spark plugs from all cylinders see High Voltage Harness and Spark Plug Maintenance in Chapter 9 of this manual for detailed removal instructions NOTE The Nc and Ne switches enable audio associated with LED illumination Position all Nc and Ne switches closest to its representative LED indicator to turn off audio 3 Disconnect both of t...

Page 288: ...operational check troubleshoot the sensor head Refer to Speed Sensor Assembly Troubleshooting in Chapter 8 9 If the SSA passes the operational check install the engine low voltage harness 25 pin connectors according to instructions in section 10 11 1 ECU or SSA Connector Installation 10 For proper operation of the engine route clamp support and protect the wires in the engine low voltage harness i...

Page 289: ...ectrical power 3 Set the aircraft Fuel Selector Valve to the OFF position 4 Cut and remove cable ties necessary to remove the solenoid coil 5 Hold the injector body with one wrench while loosening the fuel line B nut with another wrench Remove the fuel line from the fuel injector and place a protective cap on the fuel line CAUTION Fuel may flow from the fuel line once it is disconnected from the f...

Page 290: ...al or installation requires an Engine Operational Check and possible adjustment according to the Engine Operational Check instructions in Chapter 6 CAUTION Avoid introducing contaminants into the fuel injectors Work with clean hands tools and shop towels Place protective caps on the fuel injectors anytime the fuel line is not connected Never insert an object into either end of a fuel injector 4 Fl...

Page 291: ...or coil matches the number of the intended destination cylinder If the label is missing or illegible verify the identification with a DVM and the wiring diagrams in Chapter 8 and replace the label 2 Slip the fuel injector coil over the injector body Figure 10 56 and press down firmly on the coil to ensure it is seated on the base of the fuel injector body 3 Position the coil so the wire is inboard...

Page 292: ...w voltage harness connector 5 Unscrew the pressure sensor from the throttle body 10 11 13 Manifold Air Pressure Sensor Installation Procedure 1 Disconnect electrical power to the engine 2 Apply F I Sealant to the second and third threads of the pressure sensor 3 Visually inspect the mounting threads for deformation 4 Thread the sensor into the mounting boss on the throttle body Torque the sensor a...

Page 293: ...r Removal Procedure 1 Disconnect electrical power to the engine 2 Place the aircraft fuel selector valve in the OFF position 3 Cut and remove cable ties necessary to remove the fuel pressure sensor connector 4 Disconnect the engine low voltage harness circular connector from the fuel pressure sensor 5 Place a protective cap on the engine low voltage harness connector 6 Unscrew the fuel pressure se...

Page 294: ...g ring snaps to the locked position When properly mated and locked the bayonet orientation pins are visible in the locking ring pin observation port 7 For proper operation of the engine route clamp support and protect the wires in the Engine Low Voltage Harness in a manner to prevent chafing fretting and wear of the lead wires Route and secure the harness IAW Appendix C Harness Routing 8 Set the a...

Page 295: ... power to the engine 2 Cut and remove cable ties as necessary for clearance to remove the sensor 3 Loosen and fully unscrew the temperature sensor compression fitting nut and slide the sensor out of the compression fitting 4 Refer to section 10 10 3 Non EGT Sensor and Lead Wire Replacement for instructions to prepare the new sensor leads MAT Sensor MAP Sensor MAT Sensor MAP Sensor Figure 10 60 Man...

Page 296: ...ng instructions 8 Perform a FADEC Level I Diagnostics Chapter 8 Troubleshooting 10 11 18 Exhaust Gas Temperature Sensor Removal Procedure 1 Locate the EGT sensor to be removed 2 Cut the EGT sensor lead wires as close as practical to the sensor body Note the length of removed wire for reference during sensor replacement 3 Loosen the band clamp securing the sensor completely Spread the clamp to allo...

Page 297: ...e installed harness Trim the new sensor leads and existing harness leads to closely approximate the length of the original wire 3 Connect the new sensor to the engine low voltage harness using the instructions in section 10 10 2 EGT Sensor and Lead Wire Replacement 4 Route the Engine Low Voltage Harness wiring EGT sensors for cylinders 1 3 from the rear of the engine to the lower right hand quadra...

Page 298: ...THERMOCOUPLE ANGULARITY TO BE SET FOR BEST AIRFRAME INSTALLATION 4 PLACES C L C L C L C L C L C L C L C L EXHAUST CYL NO 3 EXHAUST CYL NO 1 EXHAUST CYL NO 4 EXHAUST CYL NO 2 CONNECTOR TAG EGT CYL 4 CONNECTOR TAG EGT CYL 2 CONNECTOR TAG EGT CYL 2 CONNECTOR TAG EGT CYL 2 Y Y LOCATE EGT PROBE IN EXHAUST PIPE WITHIN DIAMETER SPECIFIED 4 PLACES TORQUE CLAMP 30 35 IN LBS 4 PLACES PERMISSIBLE TO MAKE SMO...

Page 299: ...place if necessary a Unscrew the damaged adapter from the cylinder head thermal well b Install a bayonet adapter in the cylinder head s CHT thermal well Torque the bayonet adapter per torque values in Appendix B 3 Each CHT sensor is designated for installation into a specific engine cylinder by a tag indicating the engine cylinder number For example CHT CYL 2 indicates that this sensor is to be in...

Page 300: ...data connectors from the back of the HSA 6 Disconnect one end of the conductor passing through the hall effect sensor doughnut shaped protrusion on back of HSA and remove from the sensor Path from Secondary Power Switch to electrical bus Path from Secondary Power Switch to electrical bus Figure 10 63 Multi Channel HSA Connections 7 Remove the HSA from the aircraft 10 11 23 Five Lamp HSA Installati...

Page 301: ...n and removal instructions 10 11 25 Two Lamp HSA Installation Procedure 1 Install the connector on the HSA driver and secure with two screws 2 Install the lamp driver in the airframe according to the airframe manufacturer s instructions 3 Perform FADEC Level I Diagnostic Chapter 8 to verify lamp operation 10 11 26 EDI Replacement The airframe manufacturer determines the installed location of the o...

Page 302: ...at secures the ground wire from the throttle body IDLE SCREWS GROUND WIRE SCREW IDLE IDLE SCREWS GROUND WIRE SCREW Figure 10 64 Throttle Position Switch Fasteners 2 Locate the point where the throttle position switch connects to the engine low voltage harness Figure 10 65 Throttle Position Switch Wires 3 Use a small utility knife to slice the length of the heat shrink tubing 1 16 deep on each of t...

Page 303: ...nd twist the insulators toward one another Separate the three pairs of scissor connectors and discard the faulty throttle position switch Figure 10 68 Disconnect Scissor Connectors 6 Inspect the replacement throttle position switch kit contents for transit damage If the switch is serviceable continue installation If the switch is defective or parts are missing obtain a replacement Figure 10 69 Thr...

Page 304: ...an 1 8 of the wire exposed between the insulator and wire shielding Figure 10 71 Strip Wiring d Crimp the terminal to the exposed wire with the appropriate crimping tool 8 Place a two inch section of heat shrink tubing over each of the prepared engine low voltage harness wires Figure 10 72 Insert Wires in Heat Shrink Tubing 9 With the faces of the scissor connector as a pivot point connect the thr...

Page 305: ...ure the switch to the throttle body with two screws Install the ground wire on throttle body with a screw Torque the screws according to Appendix B 13 Place the cushion clamp on the throttle position switch wiring harness Position the clamp to align the clamp with the screw hole in the throttle body Arrange the throttle position switch wiring harness for proper strain relief Secure the wiring harn...

Page 306: ...Non Overhaul Removal and Replacement Teledyne Continental Motors Inc TM 10 84 IOF 240 Series Engine Maintenance Manual Change 1 31 August 2007 This Page Intentionally Left Blank ...

Page 307: ...ledyne Continental Motors Inc TM Glossary IOF 240 Series Engine Maintenance and Overhaul Manual A 1 29 November 2006 Appendix A GLOSSARY CONTENTS Appendix A Glossary A 1 A 1 Acronyms A 2 A 2 Glossary A 5 ...

Page 308: ...est Power Best Economy BPMS Boost Pump Mode Switch BSOC Brake Specific Oil Consumption BTC Before Top Dead Center CFM Cubic Feet per Minute Chnl Channel CHT Cylinder Head Temperature CSB Critical Service Bulletin DVM Digital Volt ohm Meter EBAT FAIL Backup Battery Failure EBAT FL Backup Battery Failure ECU Electronic Control Unit EGT Exhaust Gas Temperature EMI Electromagnetic Interference FAA Fed...

Page 309: ... Main Journal MPC Master Power Control MSB Mandatory Service Bulletin Nc SSA Position of Cylinder 1 Top Dead Center Ne SSA Indication of Engine Speed OEM Original Equipment Manufacturer NATO North Atlantic Treaty Organization POH Pilot s Operating Handbook PMA Parts Manufacturing Approval PPWR FAIL Primary Power Failure PPWR FL Primary Power Failure PTT Push to Test Switch RMS Root Mean Square RPM...

Page 310: ...TANAG Standardization Agreement STANAG SSA Speed Sensor Assembly STC Supplemental Type Certificate TBO Time Between Overhauls TC Type Certificate TCM Teledyne Continental Motors TDC Top Dead Center TIT Turbine Inlet Temperature TPS Throttle Position Switch TSO Technical Standard Order TSMOH Time Since Major Overhaul WOT Wide Open Throttle ...

Page 311: ...annel Each channel is assigned to a specific cylinder Crack Partial separation of material usually caused by vibration overloading internal stresses improper assembly or fatigue Critical Service Bulletin Service document based on determination by the product manufacturer to constitute a threat to continued safe operation of an aircraft or to persons or property on the ground unless the owner or op...

Page 312: ... electrical power supply to the FADEC System It is supplied by the aircraft s primary electrical bus Primary Power Circuit Breakers Circuit breakers used to protect the FADEC System s primary power supply Primary Power Switch Switch used for interrupting the primary electrical power supply to the FADEC System Propeller Strike Any incident that requires repair other than minor dressing of the blade...

Page 313: ...nance or economy Service Information Letter Service information communiqué that may be of use to the owner operator or maintainer of the aircraft Spalling Distress to a loaded surface where chips of the hardened surface are broken out Speed Sensor Assembly Indicates crankshaft speed and position for ignition and injection timing Static Seal Vital seal in the engine cylinder that consists of valve ...

Page 314: ...Glossary Teledyne Continental Motors Inc TM A 8 IOF 240 Series Engine Maintenance and Overhaul Manual 29 November 2006 This Page Intentionally Left Blank ...

Page 315: ...1 Torque Tips B 2 B 2 Cylinder Torque Procedure B 3 B 3 Torque Wrench and Extension Calculations B 4 LIST OF TABLES Table B 1 General Torque Specifications B 6 Table B 2 Assembly Torque Specifications for Fittings B 7 Table B 3 Torque Specifications for Hose Fittings B Nuts B 7 Table B 4 Component Specific Torque Specifications B 8 Table B 5 Specific Torque Values for Non lubricated Hardware B 11 ...

Page 316: ...proper plating and thread form Failure to verify a fastener s serviceability or to correctly lubricate the fastener as directed prior to installation and torquing will result in the fastener not being properly pre loaded Subsequent failure of the fastener may occur B 1 1 Torque Tips Check Table B 4 and Table B 5 first to verify whether the hardware to be torqued requires a specific torque or treat...

Page 317: ...uts must be torqued on both sides of the engine even if only one cylinder is being installed WARNING Failure to torque through bolt nuts on both sides of the engine can result in a loss of main bearing crush with main bearing shift and subsequent engine failure NOTE Through bolt nuts P N 634505 and 649496 have been superseded by P N 652541 Nut P N 634505 is a flanged six point hex nut requiring a ...

Page 318: ...the amount of force applied to the square drive enough to cause concern An offset adapter may be used with a torque wrench without affecting applied torque if the extension is positioned at a 90 degree angle in relation to the square drive adapter In any other orientation the extension alters the force applied to the fastener Figure B 2 Drive extensions Apply the formula below to determine the app...

Page 319: ... reduces the effective length of the handle The formula is the same but variable B is a negative number in Figure B 4 Let s assume the torque wrench has an effective length of 12 inches and the extension measures six inches from the center of the drive adapter to the center of the wrench If we need to torque a nut and bolt to 45 inch pounds we set the dial on the wrench in Figure B 3 to 30 45 12 6...

Page 320: ... 8 3 3125 18 5 16 18 155 175 12 9 14 6 3125 24 5 16 24 180 220 15 0 18 3 375 16 3 8 16 220 260 18 3 21 7 375 24 3 8 24 275 325 22 9 27 1 44 20 7 16 20 400 450 33 3 37 5 50 20 1 2 20 550 600 45 8 50 0 Driving Studs 250 20 1 4 50 70 4 2 5 8 3125 18 5 16 18 100 150 8 3 12 5 375 16 3 8 16 200 275 16 7 22 9 44 14 7 16 14 300 425 25 0 35 4 Pipe Plugs 062 27 1 16 27 30 40 2 5 3 3 125 27 1 8 27 60 80 5 0 ...

Page 321: ... 10 Brass Aluminum 625 200 350 88 14 10 Steel 625 300 400 Table B 3 Torque Specifications for Hose Fittings B Nuts Hose Size Hose End Fitting Material Torque In Lb 2 31 24 Brass Aluminum Fitting 50 80 2 31 24 Steel Fitting 75 120 3 38 24 Brass Aluminum Fitting 70 105 3 38 24 Steel Fitting 95 140 4 4375 20 Brass Aluminum Fitting 100 140 4 4375 20 Steel Fitting 135 190 5 500 20 Brass Aluminum Fittin...

Page 322: ...8 All 360 s IO 240 IOF 240 50 20 Nut Crankcase tie bolts nose 640 660 53 3 55 0 All models AR 62 18 Plug using crush washer 190 210 15 8 17 5 All models AR Gears 25 28 Bolt Gear to camshaft 140 160 11 7 13 3 A C E Series O 200 O 300 O 470 IO 240 IOF 240 25 28 Bolt Gear to crankshaft P N 22532 NOTE 140 160 11 7 13 3 A C Series O 200 O 300 GO 300 IO 240 IOF 240 31 24 Bolt Vac fuel pump gear to camsh...

Page 323: ...ge 180 216 15 0 18 0 All models as required 75 16 Oil filter Disposable type 192 216 16 0 18 0 All models as required 88 16 Cap Oil pressure relief valve 190 210 15 8 17 5 O 200 IO 240 O 300 TSIO 360 LTSIO 360 1 00 14 Vernatherm Oil temperature control valve 440 460 36 7 38 3 All models as required 1 375 16 LH Thd Housing tach drive 250 350 20 8 29 2 All models as required 1 25 18 Plug Special Ver...

Page 324: ...ension belt in accordance with TCM Service Bulletin M89 6 or current revision as applicable Crankgear must be heated to 300 Fahrenheit then installed on crankshaft Ensure the gear seats tightly against the end of the crankshaft by tapping lightly with a brass hammer CAUTION Improper heating of the crankshaft gear will result in damage to the gear and may lead to subsequent engine failure The instr...

Page 325: ... nut Retaining nut All FADEC 3125 32 6 24 28 2 0 2 3 Lead to spark plug B nut All 0 75 20 12 110 120 9 2 10 0 Throttle lever Screw All 8 32 1 17 5 22 5 1 5 1 9 Apply Loctite Pipe Sealant 592 Apply F I Sealant TCM part number 646940 or Loctite 569 Hydraulic Sealant Table B 6 FADEC Components Hardware Engine Model Torque in lbs ECU 50 pin Connector Securing Screws All 10 15 Signal Conditioner 25 pin...

Page 326: ...Torque Specifications Teledyne Continental Motors Inc TM B 12 IOF 240 Series Engine Maintenance Manual 29 November 2006 This Page Intentionally Left Blank ...

Page 327: ...dersize Parts C 6 C 3 Torque C 6 C 4 Safety Wiring Hardware C 7 C 5 Tab Washer Installation C 9 C 6 Helical Coil Insert Replacement C 10 C 6 1 Helical Coil Removal C 11 C 6 2 Helical Coil Insertion C 12 C 7 Stud Replacement C 13 C 7 1 Stud Removal C 13 C 7 2 Stud Installation C 13 C 7 3 Size on Size Rosan Stud Removal C 15 C 7 4 Step Type Rosan Stud Removal C 16 C 7 5 Rosan Studs Installation C 17...

Page 328: ...Figure C 4 Helical Coil Extraction Tool C 11 Figure C 5 Installing a Helical Coil Insert C 12 Figure C 6 Stud Sizes C 13 Figure C 7 Minimum material thickness for Helical Coil insertion C 14 Figure C 8 Rosan Stud Removal Tool C 16 Figure C 9 Rosan stud removal tool installed on stud C 16 Figure C 10 Rosan stud installation dimensions C 17 Figure C 11 Cotter Pin Installation C 18 Figure C 12 Instal...

Page 329: ... parts with an expired shelf life Ensure all parts are thoroughly clean refer to the Engine Cleaning section in this manual for cleaning information Use only a plastic or rawhide mallet made to tap engine parts during assembly never use a hammer Always install new gaskets o rings rubber components seals packing cotter pins tab washers safety wire and lock washers when servicing components Use only...

Page 330: ...Federal Aviation Administration FAA These instructions which include maintenance repair limits overhaul and installation are applicable only to engines and parts supplied by TCM TCM does not provide instructions relating to the installation or use of parts not manufactured or supplied by TCM Instructions provided by other engine parts manufacturers or resellers should be used for their parts TCM h...

Page 331: ...t review all service bulletins to ensure compliance with the manufacturer s requirements for continued airworthiness Replace all gaskets seals packing hoses O rings cotter pins retaining rings snap rings safety wire self locking fasteners including exhaust nuts and lock washers with new parts during assembly regardless of the type of maintenance Do not re use worn damaged or deformed fasteners Do ...

Page 332: ...ive rubber bushings Exhaust valves Exhaust valve rotocoils Intake valve rotocoils with solid valve retainers part 35971 Intake and exhaust valve keepers Inner and outer valve springs Piston pins Piston rings Pistons Rocker shafts Rockers shaft thrust washers Crankcase Through Bolts Cylinder deck stud nuts and through bolt nuts Exhaust clamps Turbocharged engines Cold Start primer diverter valves F...

Page 333: ...rdance with Appendix B of this manual CAUTION Do not apply torque above or below specified limits to align holes 2 Insert half of the required length of new safety wire through the first piece of hardware and do the following a For right hand threaded hardware install the safety wire so the strand will pull and lock clockwise b For left hand threaded hardware install the safety wire so the strand ...

Page 334: ...ers until it is taut but not overstressed 6 Insert the uppermost strand through the hole in the second piece of hardware 7 Bend and wrap the twisted wire braid around the second piece of hardware pulling the wire taut as described in the previous steps which will counter lock the hardware joined by the safety wire Repeat the previous steps for any subsequent hardware to be safety wired by this str...

Page 335: ...ole 2 Lubricate and torque hardware secured in accordance with Appendix B in this manual 3 Using a soft drift bend the lock tab on the other side of the tab washer firmly against the bolt or nut flats as shown in Figure C 3 Ensure the lock tabs are bent flat up against the hardware without protrusion as shown in top and side views to properly lock the hardware and prevent the lock tabs from breaki...

Page 336: ...t the widest part of the wire between male and female threads the diameter of the insert is equal to the nominal screw size The special finishing taps size the threaded hole to allow the pitch diameter of the female thread of the installed insert to conform to Class 3 fit with standard bolt threads or Class 4 tight fit with standard size studs The difference in fit is due to a difference in pitch ...

Page 337: ...Removal Procedure 1 Use the proper size extracting tool Figure C 4 for the nominal thread size 2 Tap the extracting tool into the helical coil insert until the sharp edges of the tool dig firmly into the helical coil insert 3 Turn the tool to the left and back out the helical coil until it is free Figure C 4 Helical Coil Extraction Tool ...

Page 338: ...ped hole as shown in Figure C 5 5 The outer end of the insert must lie within the first full thread of the hole 6 Break off the driving tang of a notched helical coil by bending it back and forth across the hole with long needle nose pliers or with a special tang break off tool 7 Once the helical coil insert is installed the remaining wall thickness edge distance to the helical coil must not be le...

Page 339: ...slowly to avoid heating the casting 2 To remove a stud which cannot be removed with a standard stud extractor tool drill a hole matching the diameter of a splined stud extractor tool through the center of the stud Insert the splined stud extractor through the drilled center of the stud and unscrew the stud 3 Examine the course thread end of the damaged stud before discarding it to determine the co...

Page 340: ...diameter remains after tapping for the helical coil insert Refer to Figure C 7 5 If the hole is blind or if the hole goes through to a cavity subject to leakage coat the new stud s course thread with High Strength Adhesive TCM part number 646941 6 Drive the new stud with a tee handle stud driver Turn it slowly and compare the torque values listed in Appendix B 7 Drive the stud until it reaches the...

Page 341: ...ole and drill to the specified depth Table C 1 This method should cut the engagement between the stud serrations and the internal serrations of the lock ring Table C 1 Rosan Stud Primary Secondary Removal Drill Diameters Depths Cylinder Exhaust Port Stud Primary Removal Drill Secondary Removal Drill Basic Stud Number Diameter Minimum Depth Diameter 0 015 Depth 0 164 dia SFC164 1 16 0 062 0 250 3 1...

Page 342: ...9 to mill the lock ring to the appropriate depth 2 Apply removal torque to remove the stud 3 Lift out the remaining portions of the lock ring 4 Carefully use a sharp punch to break away the remaining portion from the cylinder head Figure C 8 Rosan Stud Removal Tool Figure C 9 Rosan stud removal tool installed on stud C 7 4 2 Step Type Rosan Stud Removal Method 2 Procedure 1 Follow the procedure in...

Page 343: ...p type may be installed using the appropriate wrench Install the stud to the dimensions specified in Figure C 10 CAUTION Location of the flange is important in preventing the lock ring drive tool from making contact with surface A in Figure C 10 Any impact or pressure on surface A may damage the threads in the cylinder head resulting in a loose fit Figure C 10 Rosan stud installation dimensions ...

Page 344: ...ary 4 Insert the cotter pin through a hole with the head seated firmly in the slot of the nut 5 Spread the exposed ends of the cotter pin Bend the ends over the flat on the nut and the end of the bolt CAUTION Do not use pliers with cutting jaws side cutters end cutters etc to bend back the cotter pin ends The sharp edges cause nicks which will weaken the cotter pin to the extent that it can become...

Page 345: ...hin translucent coat of Gasket Maker not to exceed 010 inches in thickness to the surface directly from the tube For small parts use a polyester urethane sponge or a short nap roller saturated with Gasket Maker to apply the sealant to the part 4 Once Gasket Maker has been applied evenly torque the assembly into place 5 Wipe away excess sealant with chlorinated solvent 6 To remove Gasket Maker from...

Page 346: ...rittleness cracks wrinkles damage or deformities Do not use a gasket with obvious defects even if new replace with a new manufacturer specified gasket Verify the gasket surfaces are clean and free of nicks burrs oil and grit WARNING Gaskets and components must be properly positioned with the hardware torqued and safety wired as required during assembly to prevent oil loss CAUTION Do not install br...

Page 347: ...wrench on both mating connections to avoid applying excessive torque to the fittings Securely tighten fittings and torque to the specified value in Appendix B Torque Values Torque the hose or tubing end fitting while maintaining sufficient force on adjacent fittings Figure C 12 to prevent twisting and shear loads CAUTION Do not exceed specified torque values 2 Support the fitting adjacent to the o...

Page 348: ...low voltage harness is 300 F 149 C the low voltage harness must not come in contact with a surface hotter than 250 F 121 C 1 Gather the leads of the harness together use cable ties to stalk the various sections of the harness 2 Secure the harness stalks to the engine and airframe Refer to Figure C 13 The butterfly technique is the preferred method for securing the harness to the aircraft engine st...

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